Electronically commutated motor, stationary and rotatable assemblies therefore, and lamination

ABSTRACT

A lamination adapted to be used in a dynamoelectric machine. The lamination has a body of generally thin ferromagnetic material, and a plurality of pole sections are spaced apart from each other generally about the body. A plurality of means on the body are interposed between adjacent ones of the pole sections for bridging therebetween, respectively, and a plurality of other pole sections on the body are interposed in spaced relation between the adjacent ones of the first named pole sections, respectively. A plurality of pairs of other means on the body are interposed between the adjacent ones of the first named pole sections and the other pole sections for bridging therebetween, respectively. 
     An electronically commutated motor, a stationary assembly therefor, and a rotatable assembly therefor are also disclosed.

FIELD OF THE INVENTION

This invention relates in general to dynamoelectric machines and inparticular to an electronically commutated motor, a stationary assemblyand a rotatable assembly therefor, and a lamination.

BACKGROUND OF THE INVENTION

In the past conventional DC motors, commutation was effected by brushesriding on a segmented commutator so as to control the currents flowingthrough the armature winding sections of such past conventional DCmotors. Of course, one of the disadvantageous or undesirable featuresattendent to the above discussed commutated DC motors is believed to bethat wear of the brushes thereof necessitated frequent brushreplacement. Other disadvantageous features of these past commutated DCmotors are believed to be that sparking may have occurred between thebrushes and segmented commutator thereof which not only may haveeffected RF interference but also may have limited the use of suchcommutated DC motors in some critical or particular environmentalapplications.

Various circuit and motor design schemes have been utilized in the pastto develop various types of brushless DC motors, and one such scheme isshown in the David M. Erdman U.S. Pat. NO. 4,005,347 issued Jan. 25,1977 and U.S. Pat. No. 4,015,182 issued Mar. 29, 1975, each of which areincorporated herein by reference. In these patents, a brushless DC motorhas a stator with a plurality of windings therein, a rotor having aplurality of constant magnetic polar regions, and means for sensing therelative position of the rotor polar regions with respect to the stator.Positive signals developed by the position sensing means were processedby circuitry for selectively energizing the windings of the motor.

In the present day clothes washing or laundry machines having agenerally coaxially arranged agitator and a spin tub, the agitator isrotated with an oscillating movement, and the rotation of the spin tubis unidirectional at a speed appreciably greater than that of theagitator oscillation. Of course, many different transmission mechanismand drive schemes have been employed in the past to effect theaforementioned particular oscillation and unidirectional rotation of theagitator and spin tub; however, it is believed that a disadvantageous orundesirable feature of such past schemes was that they were too costlyand/or too complicated not only from the viewpoint of manufacture butalso from the viewpoint of power usage and maintenance by the consumer.

SUMMARY OF THE INVENTION

Among the several objects of the invention may be noted the provision ofan improved electronically commutated motor, an improved stationaryassembly and rotatable assembly thereof, and an improved laminationwhich overcome the above discussed disadvantageous or undesirablefeatures, as well as others, of the prior art; the provision of suchimproved electronically commutated motor and such improved stationaryand rotatable assemblies therefor which are of a compact size and yetprovide a comparatively large output rating; the provision of suchimproved rotatable assembly in which means for magnetically defining thepolarity of some pole sections from adjacent pole sections is effectiveto retain the some pole sections against displacement from the rotatableassembly; and the provision of such improved electronically commutatedmotor, stationary and rotatable assemblies, and lamination which arerespectively simplistic in design, easily assembled and economicallymanufactured. These as well as other objects and advantageous featuresof the present invention will be in part apparent and in part pointedout hereinafter.

In general, an electronically commutated motor has a rotatable assemblywith a plurality of poles, and a stationary assembly disposed inmagnetic coupling relation with the rotatable assembly. The stationaryassembly includes a plurality of winding receiving slots with the numberof slots in said plurality thereof being different than the product ofan integer multiplied by the number of the poles in the rotatableassembly, and a multi-stage winding arrangement having a plurality ofwinding stages with each winding stage having a plurality of coilsdistributed in the slots generally about the stationary assembly.

Also in general, an electronically commutated motor in one form of theinvention has a pair of ferro-magnetic cores arranged generallycoaxially with each other with one of the cores being rotatable relativeto the other thereof, and a plurality of winding receiving slots isprovided in one of the one and other cores. A multi-stage windingarrangement includes a plurality of winding stages adapted to be excitedin at least one preselected sequence, and each of the winding stages hasa plurality of coils with each of the coils having at least oneconductor turn with side turn portions thereof received in the slots.Some of the coils in the each winding stage have side turn portionsthereof sharing slots only with side turn portions of other of the coilsin the same winding stage. Two pairs of the coils in one of the windingstages of the plurality thereof have side turn portions sharing slotswith the side turn portions of two pairs of the coils in another two ofthe winding stages of the plurality thereof, and another pair of coilsin the another two winding stages have side turn portions which do notshare slots, respectively. A plurality of discrete poles are arrangedgenerally about the other of the one and other cores so as to bemagnetically coupled with the each winding stage upon the excitationthereof, respectively.

Also in general and in one form of the invention, another electronicallycommutated motor has a pair of ferro-magnetic cores arranged generallycoaxially with each other with one of the cores being rotatable relativeto the other thereof. A plurality of winding stages arranged with one ofthe one and other cores are adapted to be excited in at least onepreselected sequence, and a plurality of poles are arranged generallyabout the other of the one and other cores so as to be disposed inmagnetic coupling relation with the winding stages upon the energizationthereof, respectively. A plurality of means are arranged generally aboutthe other of the one and other cores for receiving some of the poles inspaced relation between adjacent other poles, respectively, and means isprovided in the receiving means for maintaining the some poles againstdisplacement from the receiving means and also for magnetically definingthe polarity of the some poles from that of the adjacent other poles.The maintaining and defining means includes a plurality of sets ofmagnetic material elements arranged between the some poles and theadjacent other poles, and a hardenable nonmagnetic material solidifiedat least within the receiving means in engagement between the somepoles, the adjacent other poles, and the magnetic material element sets,respectively.

Still in general and in one form of the invention, a stationary assemblyadapted to be used in an electronically commutated motor is providedwith a ferro-magnetic core having a plurality of winding receiving slotstherein. A multi-stage winding arrangement has a plurality of windingstages each having a plurality of coils with each of the coils having atleast one conductor turn with side turn portions thereof received in theslots of the plurality thereof. Some of the coils in the each windingstage have side turn portions thereof sharing slots only with side turnportions of other of the coils in the same winding stage. Two pairs ofthe coils in one of the winding stages of the plurality thereof haveside turn portions sharing slots with side turn portions of two pairs ofthe coils in another two of the winding stages of the plurality thereof,respectively. Another two pair of the coils in the another two windingstages each have one side turn portion which do not share slots.

Further in general and in one form of the invention, a rotatableassembly adapted for use in a dynamoelectric machine has aferro-magnetic core, a plurality of ferro-magnetic pole sections and aplurality of means in the core for receiving the pole sections. Means isprovided in the receiving means for magnetically defining the polarityof the pole sections from adjacent parts of the core and for retainingthe pole sections against displacement from the receiving means,respectively. The defining and retaining means includes a plurality ofsets of magnetic material elements abutted between the pole sections andthe adjacent parts of the core, and a hardenable non-magnetic materialsolidified in place at least within the receiving means between the polesections, the adjacent parts of the core and the magnetic materialelement sets, respectively.

In general and in one form of the invention, a lamination adapted to beused in a core of dynamoelectric machine has a unitary body of generallythin ferro-magnetic material. A plurality of pole sections are spacedapart from each other generally about the body, and a plurality of meanson the body are interposed between adjacent ones of the pole sectionsfor bridging therebetween, respectively. A plurality of other polesections on the body are interposed in spaced relation between theadjacent ones of said first named pole sections, and a plurality ofpairs of other means on the body are interposed between the adjacentones of the first named pole sections and the other pole sections forbridging therebetween, respectively.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is an enlarged plan view of a punched out rotatable assemblylamination in one form of the invention;

FIG. 2 is a functional box diagram illustrating a method of making acore for use in a rotatable assembly for a dynamoelectric machine;

FIGS. 3-8 are enlarged partial views of the lamination of FIG. 1 andillustrate principles which may be practiced in the method representedby the functional box diagram of FIG. 2;

FIG. 9 is an end view of a rotatable assembly in one form of theinvention which may be formed in accordance with the method illustratedby the functional box diagram of FIG. 2;

FIG. 10 is a sectional view taken along line 10--10 of FIG. 9.

FIG. 11 is a sectional view taken along line 11--11 of FIG. 10;

FIG. 12 is a graphical representation illustrating the magneticproperties of magnetic material elements utilized in the rotatableassembly of FIGS. 9-11 as well as those of other magnetic materialelements.

FIG. 13 is a greatly enlarged end view illustrating a stationaryassembly with a plurality of winding stages schematically shown andarranged in the stationary assembly in one form of the invention;

FIG. 14 is a partial sectional view taken from FIG. 13 illustrating thedisposition of coils of the winding stages with a coil receiving slot ofthe stationary assembly;

FIG. 15 is a schematic diagram illustrating the distribution of thewinding stages in the coil receiving slots of the stationary assembly inFIG. 13;

FIGS. 15A and 15B are schematic diagrams illustrating the distributionof alternative winding stages as they may be arranged in the coilreceiving slots of the stationary assembly of FIG. 3, respectively;

FIG. 16 is a plan view illustrating an electronically commutated motorin one form of the invention;

FIG. 17 is an end view of the electronically commutated motor of FIG.16;

FIG. 18 is a sectional view taken along line 18--18 of FIG. 17;

FIG. 19 is a diagrammatic representation illustrating positions of polesections in the rotatable assembly of the electronically commutatedmotor of FIGS. 16-18 with respect to the winding stages in thestationary assembly thereof at the instant one of the winding stages iscommutated so as to be excited;

FIG. 20 is a graphical representation of the voltage which may bedeveloped upon the selective energization of the winding stages in theelectronically commutated motor of FIGS. 15-19;

FIG. 21 is a sectional view illustrating a transmission mechanismadapted for use in a laundry machine;

FIGS. 22-24 are sectional views taken along lines 22--22, 23--23 and24--24 in FIG. 21, respectively;

FIG. 25 is a partial sectional view illustrating a laundry machine aswell as a drive therefor;

FIG. 26 is an enlarged partial view partially in cross-section takenfrom FIG. 25;

FIGS. 27 and 28 are partial sectional views illustrating alternativepole sections which may be utilized in the lamination of FIG. 1, therotatable assembly of FIGS. 9-11 and the method of making such in FIGS.2-8 in one form of the invention, respectively;

FIG. 29 is an elevational view partially in section illustrating analternative rotatable assembly in one form of the invention which may beutilized with the stationary assembly in the electronically commutatedmotor of FIGS. 15-19;

FIG. 30 is a sectional view taken along lines 30--30 in FIG. 29;

FIG. 31 is a functional box diagram illustrating a method of making acore for use in the rotatable assembly of FIG. 29; and

FIGS. 32 and 33 are enlarged partial views of the core of FIGS. 29 and30 and illustrate principles which may be practiced in the methodrepresented by the functional box diagram of FIG. 31.

Corresponding reference characters refer to corresponding partsthroughout the several views of the drawings.

The exemplifications set out herein illustrate the preferred embodimentsof the invention in one form thereof, and such exemplifications are notto be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in general, there is shown at 41 alamination in one form of the invention adapted to be used in aferro-magnetic core or rotor 43 of a dynamoelectric machine, such as anelectronically commutated motor or brushless DC motor 45 or the like forinstance (FIGS. 1, 9-11 and 16-18). Lamination 41 has a unitary body 47blanked or otherwise formed from a generally thin ferromagneticmaterial, such as an electrical grade sheet steel or the like forinstance, and a plurality of pole sections 49 are spaced apart from eachother generally about the body (FIG. 1). A plurality of means, such asinner peripheral bridges or connecting arms 51 for instance, on body 47are interposed between adjacent ones of pole sections 49 for bridgingtherebetween, respectively. A plurality of other pole sections 53 ofbody 47 are interposed in spaced relation between the adjacent ones ofpole sections 49, and a plurality of sets or pairs of other means, suchas outer peripheral bridges or connecting arms 55 or the like forinstance, are interposed between the adjacent ones of pole sections 49and pole sections 53 for bridging therebetween, respectively.

More particularly and with specific reference to FIG. 1, body 47 oflamination 41 has a pair of radially spaced outer and inner peripheraledges 57, 59 with the inner peripheral edge defining a generallycentrally located shaft receiving bore or the like through the body, asdiscussed hereinafter. A plurality of openings, such as generallyV-shaped apertures or slots 61 for instance, are provided through body47 between peripheral edges 57,59 thereof, respectively, and theopenings are arranged with each other in generally arcuate spacedrelation about the body. Thus, pole sections 49 respectively are definedon body 47 generally between adjacent ones of openings 61.

Each of openings 61 has a pair of leg parts 63,65 tapering toward eachother generally in a direction from outer peripheral edge 57 towardinner peripheral edge 59. Leg parts 63, 65 each have a pair of oppositeside edges 67,69 and 71,73 and a pair of end edges or end portions 75,77are interposed between the side edges generally adjacent outerperipheral edge 57 while a common end edge or end portion 79 isinterposed between side edges 67,73 generally adjacent inner peripheraledge 59. Thus, side edges 67,73 of leg parts 63,65 are provided onadjacent ones of pole sections, 49, and side edges 69,71 are provided onpole sections 53 between the adjacent ones of pole sections 49,respectively. Further, bridging means or inner bridges 51 are definedbetween inner peripheral edge 59 and common end edge 79 so as tointegrally interconnect between pole sections 49, and sets or pairs ofbridging means or outer bridges 55 are arranged between outer peripheraledge 57 and each end edge 75,77 of leg parts 63,65 in openings 61 so asto define narrow peripheral bands or strips on body 47 which may bedeformed generally radially inwardly toward the leg parts, respectively,as discussed in detail hereinafter. Thus, bridges or bridge pairs 55 areintegrally interconnected between each pole section 53 and the polesections 49 adjacent thereto, respectively. Pole sections 53 are definedgenerally between side edges 69,71 of leg parts 63,65 in openings 61 andextend therebetween generally radially inwardly from outer peripheraledge 57 toward inner peripheral edge 59. The radially inner ends of sideedges 69,71 intersect with a free end edge 81 on pole section 53 whichis arranged generally in opposite or facing relation with common endedge 79, and a pair of opposite tabs or abutments 83,85 integrallyformed on each of pole sections 53 extend generally from the oppositeside edges of the pole section at least generally adjacent the free endedge into leg parts 63,65 of openings 61, respectively. While openings61 are described herein as being generally V-shaped in lamination 41, itis contemplated that other openings having different shapes may beemployed within the scope of the invention so as to meet the objectsthereof, and of course, such different shaped openings would also alterthe shape of the pole sections.

Referring again in general to the drawings and recapitulating at leastin part with respect to the foregoing, there is illustrated a method formaking, manufacturing or assembling rotor 43 which has a plurality ofdiscrete polar regions or areas, such as generally defined by polesections 49,53, with such polar regions or pole sections being spacedapart generally about a peripheral portion 87 of the rotor (FIGS. 3-10).In this method, pole sections 53 are positioned, disposed or otherwiselocated or arranged in preselected positions spaced between adjacentones of pole sections 49 (FIGS. 1 and 3), and a plurality of sets orpairs of magnetic material elements 89,91 are disposed or otherwisearranged between pole sections 53 and the adjacent ones of pole sections49, respectively (FIGS. 4 and 5). A hardenable non-magnetic material 93is provided in rotor 43 between pole sections 49,53 and magneticmaterial elements 89,91, so as to be solidified in place therebetween,and the non-magnetic material acts along with the magnetic materialelements to effect magnetic polarity definition between pole sections49,53 while also retaining or maintaining the magnetic material elementsand pole sections 53 in their preselected positions againstdisplacement, respectively (FIG. 6). Hardenable material 93 may bealuminum, copper or respective alloys thereof or other non-magneticmaterials having good electrical conductivity properties.

More particularly and with specific reference to FIGS. 1-8 and 10, aplurality of laminations 41 are stacked or otherwise assembled togethergenerally in juxtaposed or face-to-face relation, as illustratedgenerally in FIGS. 3 and 10, thereby to form a lamination stack 95having a predetermined stack height or length required for rotor 43 ofFIG. 10, and the stacking of the laminations is illustrated byfunctional diagram box 97 in FIG. 2. Either during or subsequent to theabove discussed stacking or laminations 41 into rotor stack 95, openings61 of the lamination are respectively aligned or otherwise arranged witheach other so as to define a plurality of slots or slot openings 99which extend through rotor 43 between a pair of opposite ends or endportions 101, 103 thereof, as best seen in FIGS. 3 and 10. Even thoughthe alignment of openings 61 so as to form slots 99 may be accomplishedduring the stacking of laminations 41, as discussed above, such openingalignment is illustrated in a separate functional diagram box 105 ofFIG. 2. Although slots 99 are shown as extending generally axiallythrough rotor 43 between opposite ends 101, 103 thereof, it iscontemplated that the slots may be slightly skewed during the alignmentof openings 61 within the scope of the invention so as to meet at leastsome of the objects thereof. Further and albeit not shown for the sakeof brevity, it is to be understood that suitable equipment may beemployed to effect the stacking of laminations 41 and the alignment ofopenings 61 so as to form slots 99 through stator 43. Of course, it mayalso be noted that upon the above discussed alignment of openings 61,outer and inner peripheral edges 57, 59 of laminations 41 in stack 95thereof are also generally aligned or otherwise arranged with each otherso that outer peripheral edges 57 generally define peripheral portion orwall 87 on rotor 43 between opposite ends 101, 103 thereof and innerperipherial edges 59 generally define a shaft receiving bore 107extending through the rotor between the opposite ends thereof,respectively, as best seen in FIG. 10. Of course, the particular edgeson laminations 41 which define openings 61 therethrough, as discussedhereinabove, are also disposed generally in alignment with each otherupon the alignment of the openings so as to form slots 99 in rotor stack95, and such particular edges in their aligned formation define wall orwall means of the slot; however, for the sake of brevity, such slotwalls will be designated by the reference numeral of such particularedges corresponding thereto when referred to hereinafter.

Magnetic material elements 89,91, such as elongate block or bar magnetsfor instance, are provided with a pair of opposite generally flatsurfaces or faces 109, 111 interposed between a pair of oppositegenerally flat intermediate surfaces or end faces 113, 115,respectively. When openings 61 of laminations 41 are aligned throughrotor stack 95 to define slots 99 thereof, as discussed above, magnets89,91 are respectively inserted, placed, positioned or otherwisedisposed within of the slots so that opposite faces 109,111 of themagnets are arranged generally in facing relation with oppositesidewalls 67,69 and 71, 73 of the slots extending through rotor stack95, respectively, as shown in FIG. 4. In other words, opposite faces109, 111 of magnets 89,91 extend generally in face-to-face relation withpole sections 49,53 generally throughout their lengths with respect toslots 99 between opposite end faces 101, 103 of rotor stack 95. Ofcourse, due to manufacturing tolerances for both lamination 43 andmagnets 89, 91, it is contemplated that the magnets may be generallyloosely positioned in slots 99. Upon the placement of magnets 89,91within slots 99, opposite intermediate surfaces 115 of the magnets maybe seated or otherwise located on opposite tabs 83,85 of pole sections53 so that the other opposite intermediate surface 113 of the magnetsare spaced from outer bridges or bridge sections 55 in rotor stack 95.Magnets 89,91 are available from TDK Electronics Co., Ltd., 2-14-6,Uchikanda, Chiyoda-ku, Tokyo, Japan under Model No. TDK-30 and generallyhave the magnetic characteristics as illustrated in the graph of FIG.12. The placement of magnets 89,91 in slots 99 is illustrated infunctional diagram box 117 in FIG. 2. While the particular shape andmagnetic characteristics of magnets 89,91 are disclosed herein, it iscontemplated that other magnets having other shapes and/or othermagnetic characteristics may be employed in rotor 43 within the scope ofthe invention so as to meet the objects thereof, and it is alsocontemplated that more than two magnets may be utilized in thedefinition of a polar region of the rotor within the scope of theinvention so as to meet the objects thereof. For the sake of comparison,the magnetic characteristics of some of the above mentioned othermagnets which might be employed in rotor 43 are also shown in the graphof FIG. 12.

After the placement of magnets 89,91 within slots 99 of rotor stack 95,outer bridges 55 of laminations 41 are displaced or otherwise deformedgenerally along the entire length of the rotor stack between oppositeends 101, 103 thereof in a direction generally inwardly of the corestack or toward leg parts 63,65 of the slots, as shown in FIG. 5.Bridges 55 in rotor stack 95 may be so deformed by a tool 119, asillustrated schematically in FIG. 5, forced against outer peripheralportion 87 of rotor 43 generally along the bridges. In response to thisdeformation of outer bridges 55, pole sections 53 and magnets 89,91 aremovable therewith and relative to pole sections 49 so that oppositefaces 109, 111 of the magnets are abutted or otherwise engaged generallyin face-to-face relation with pole sections 49 and pole sections 53,respectively. Of course, this deformation of outer bridges 55 and theresulting movement of pole sections 53 and magnets 89,91 is just greatenough to take up the aforementioned manufacturing tolerancestherebetween to insure that opposite faces 109,111 of the magnets areengaged in the face-to-face relation with pole sections 49,53 generallyalong the lengths thereof in slots 99. However, if the aforementionedmanufacturing tolerances between magnets 89,91 and pole sections 49,53are satisfactory so as to afford an acceptable or desirable fluxtransfer relation therebetween, it is contemplated that the abovediscussed deformation of bridges 55, as illustrated in functionaldiagram box 121, of FIG. 2, may be omitted from the method ofmanufacturing rotor 43 within the scope of the invention so as to meetthe objects thereof. Albeit not shown for the purpose of disclosurebrevity, it is understood that suitable equipment may be utilized toeffect the deformation of outer bridges 55 generally simultaneously orin any given order so as to effect the tolerance take-up movement ofpole sections 53 and magnets 89,91, as discussed above.

With magnets 89,91 so respectively positioned within slots 99 inabutment between pole sections 49, 53, a squirrel cage winding,indicated generally at 123 in FIGS. 9 and 10, is integrally formed withrotor stack 95, and the squirrel cage winding comprises a plurality ofrotor bars 125 extending through the slots and integral with a pair ofopposite generally annular end rings 127, 129 disposed on opposite ends101, 103 of the core stack between peripheral portion 87 and bore 107thereof, respectively. If desired, a plurality of fan blades, 131 mayalso be integrally formed with end rings 127, 129, respectively. Ofcourse, it is contemplated that suitable equipment may be employed toeffect the formation of squirrel cage winding 123 with rotor tack 95;however, for the sake of brevity, a disclosure of such equipment isomitted. In the formation of squirrel cage winding 123, hardenablematerial 93 is provided or otherwise introduced into the intersticeswithin slots 99 generally about magnets 89,91 therein and between polesections 49, 53 and inner and outer bridges 55,59, respectively, asshown in FIG. 6. Thus, hardenable materials 93 fills the aforementionedinterstices within slots 99 throughout the lengths thereof betweenopposite ends 101, 103 of rotor stack 95, so as to define bars 125therein, and generally simultaneously therewith, opposite end rings 127,129 of the hardenable material are formed or otherwise defined onopposite ends 101, 103 of the rotor stack, respectively. Of course,hardenable material 93 may be poured, cast, injected or otherwiseprovided in slots 99 of rotor stack 95 so as to effect the generallysimultaneous formation of bars 125 and opposite end rings 127, 129 ofsquirrel cage winding 123 with the rotor stack upon the solidificationin place of the hardenable material. The formation of squirrel cagewinding 123 is illustrated generally by a functional diagram box 133 inFIG. 2.

When hardenable material 93 is solidified in situ so as to form squirrelcage winding 123 on rotor stack 95, as discussed above, a part of eachdeformed outer bridge 55 may be removed from peripheral portion 87 ofthe core stack so as to provide a plurality of grooves or spaces 135between pole sections 49, 53 disjoining or otherwise disassociating themalong the entire length of the core stack between opposite ends 101, 103thereof, respectively, as shown in FIG. 7 and illustrated by afunctional diagram box 137 in FIG. 2 To effect this aforementioneddisjoinder of pole sections 49, 53, a tool, such as a milling orbroaching tool or the like for instance as schematically illustrated at139 in FIG. 7, may be engaged with deformed outer bridges 55 onperipheral portion 87 of rotor stack 95 and operated to machine awayportions or sections of the bridges along the entire length of the corestack between opposite ends 101, 103 thereof so as to effect thephysical separation or disjoinder of pole sections 49, 53. However, itshould be noted that upon the above described disjoinder of polesections 49, 53, grooves 135 are located or otherwise arranged betweenthe pole sections so that remaining parts or sections of deformedbridges 45 define a pair of opposed flanges or extensions 141, 143 onadjacent ones of pole sections 49 which extend therefrom in part overleg parts 63,65 of slots 99 along the length of rotor stack 95 betweenopposite ends 101, 103 thereof, respectively. It is, of course,contemplated that deformed outer bridges 55 may be machined generallysimultaneously or in any selected order within the scope of theinvention so as to meet at least some of the objects thereof. Also, itis contemplated that suitable equipment may be utilized to effect themachining of deformed outer bridges 55, but for the sake of brevity, adisclosure of such equipment is omitted.

Upon the above discussed disjoinder of pole sections 49, 53, it may benoted that portions of hardenable material 93 are predeterminatelysolidified in place or otherwise arranged between the pole sectionswithin slots 99 so as to be abutted or otherwise engaged between opposedflanges 141, 143 on pole sections 49 and opposite surfaces 113 ofmagnets 89, 91. Since opposite surfaces 115 of magnets 89,91 are seatedon opposite tabs 83,85 of pole sections 53, the coaction of the magnetsand the aforementioned portions of hardenable material 93 engagedbetween flanges 141, 143 and opposite surfaces 113 of the magnets serveto cage or otherwise retain or maintain pole sections 53 againstdisplacement from slots 99, respectively. Further, it may also be notedthat the disposition of hardenable material 93 and magnets 89, 91 withinslots 99 in abutment between pole sections 49,53 also serve to effectthe magnetic polarity definition between the pole sections. In otherwords, hardenable material 93 and magnets 89,91 in their respectiveabutting or spacing relation between pole sections 49,53 effectivelymagnetically define the polarity of pole sections 53 from that ofadjacent ones of pole sections 49 which are integrally interconnectedwith each other by inner bridges 59. Thus, in response to the magneticaffect of magnets 89,91, pole sections 53 are each magnetized so as tohave the same polarity while pole sections 49, which are integrallyinterconnected by inner bridges 59, each are magnetized so as to have apolarity opposite to that of pole sections 53. In view of the foregoing,it may be further noted that pole sections 49,53 define discreteconstant polar regions or areas extending generally about peripheralportion 87 of rotor 43 and between opposite ends 101, 103 thereof,respectively.

Subsequent to the disjoinder of pole sections 49, 53 in rotor stack 95,peripheral portion 87 thereof may be turned or otherwise machined toprovide the rotor stack with a preselected diameter. As seen in FIG. 8and as illustrated by a functional diagram box 145 in FIG. 2, outerperipheral edges 57 of laminations 41 in rotor stack 95 may be engagedand machined by a tool, such as a lathe bit or the like for instanceillustrated schematically at 147 in FIG. 8, thereby to provideperipheral portion 87 of the rotor stack with a preselected outsidediameter generally between opposite ends 101, 103 thereof. While theabove discussed turning of rotor stack 95 to the preselected outsidediameter thereof may be performed by certain equipment, such as a latheor the like for instance, a disclosure of such equipment is omitted forthe sake of brevity.

With respect to the magnetization of magnets 89,91, is it preferred thatsuch magnetization be accomplished upon the assembly of electronicallycommutated motor 45, as discussed hereinafter. In other words, onceelectronically commutated motor 45 is assembed together, pole sections49,53 of rotor 43 may be aligned under a particular one of the windingstages of the commutated motors, and when so aligned, a relatively highcurrent may be passed through such particular one winding stage therebyto effect the magnetization of magnets 89,91, as well known in the art.Of course, it is contemplated that suitable equipment may be utilized toeffect the magnetization of magnets 89,91 in rotor 43, as discussedabove, but for the sake of brevity, a description of such suitableequipment is omitted. While the magnetization of magnets 89,91 in rotor43 as discussed above is preferred, it is also contemplated that themagnets could be magnetized before they are disposed in rotor slots 99or subsequent to the completion of the assembly of rotor 43 bymagnetizing pole sections 49,53 thereof all at the same time within thescope of the invention so as to meet at least some of the objectsthereof.

Referring again in general to the drawings and recapitulating at leastin part with respect to the foregoing, there is shown a rotatableassembly 151 in one form of the invention which is adapted to be used indynamoelectric machine 45 (FIGS. 9-11 and 18). Rotatable assembly 151comprises rotor 43 having a plurality of means, such as slots 99 whichmay be thought of as including grooves 135 for receiving pole sections53 in the rotor (FIGS. 10 and 11). Means, indicated generally at 153, isprovided in receiving means or slots 99 for defining the magneticpolarity of pole sections 53 with respect to adjacent parts of rotor 43,such as for instance the ones of pole sections 49 of the rotor adjacentpole sections 53, and for retaining or maintaining pole sections 53against displacement from the slots, respectively (FIGS. 10 and 11).Defining and retaining means 153 include magnets 89,91 disposed betweenpole sections 49,53 and hardenable material 93 solidified in place inslots 99 between pole sections 49,53 and the magnets, respectively(FIGS. 10 and 11).

More particularly and with specific reference to FIGS. 9-11, rotor 43has its shaft receiving bore 107 defined therein by inner peripheraledges 59 of laminations 41 in rotor stack 95, and the bore intersectswith opposite ends 101, 103 of rotor 43, respectively, as previouslymentioned. A shaft 155 is disposed in bore 107 in displacementpreventing engagement with rotor 43, and a pair of opposite extensionsor end sections 157,159 on the shaft extend generally axially beyondopposite ends 101, 103 of rotor 43, the shaft extensions being adaptedto be suitably journaled in dynamoelectric machine 45, as discussedhereinafter. Rotor 43 and shaft 155 may be assembled together in thedisplacement preventing engagement by suitable means, such aspress-fitting or heat shrinking for instance. In the preferredembodiment of rotatable assembly 151, rotor 43 is heated to effectexpansion of bore 107 therein, and at least one of the rotor and shaft155 are moved with respect to the other thereof in order to position thebore in a preselected coaxial location about the shaft with respect toat least one of opposite extensions 157, 159 thereof. When so located,rotor 43 is allowed to cool thereby to effect the contraction or heatshrinking of the rotor and its bore 107 into the displacement preventingor gripping engagement with shaft 155 in the preselected coaxiallocation thereon. While rotatable assembly 151 is disclosed having eightpoles, it is contemplated that other rotatable assemblies havingdifferent numbers of poles may be utilized within the scope of theinvention so as to meet at least some of the objects thereof.

With reference again in general to the drawings, a stationary assembly161 shown in one form of the invention is adapted to be used inelectronically commutated motor 45 (FIGS. 13-18). Stationary assembly161 comprises a ferro-magnetic core or stator 163 with a plurality ofwinding receiving slots 165 disposed generally thereabout (FIGS. 13 and14). A multi-stage winding arrangement, indicated generally at 167,includes a plurality of winding stages 171, 173, 175 each having aplurality of coils 177-1 to 177-8, 179-1 to 179-8 and 181-1 to 181-8with each of the coils thereof having at least one conductor turn 183with opposite side portions 185 received or otherwise accommodated inrespective ones of slots 165, respectively (FIGS. 13 and 15). Most, orat least some, of coils 177, 179, 181 in winding stages 171, 173, 175have a side turn portion 185 thereof sharing a respective one of slots165 with a side turn portion of other coils in the same winding stage,respectively (FIGS. 13 and 15). Two pairs of coils 179 in winding stage173 have a side turn portion 185 thereof sharing respective ones ofslots 165 with two pairs of coils 177, 181 in winding stages 171, 175,and two pairs of coils 167, 181 of winding stages 171, 175 have a sideturn portion thereof which do not share a respective one of slots 165,respectively (FIGS. 13 and 15).

More particularly and with specific reference to FIGS. 13-15, and 18,stator 163 has a generally cylindric shaped peripheral portion orsection 187 interposed or interconnected between a pair of opposite endfaces or portions 189, 191 of the stator; however, it is contemplatedthat other stators having various other shapes, such as oppositeperipheral flats thereon for instance as well as other slot shapes orconfigurations, may be utilized within the scope of the invention so asto meet at least some of the objects thereof. A plurality of teeth 193are integrally formed on stator 163 between adjacent ones of windingslots 165 with the teeth and slots extending generally axially throughthe core so as to intersect with opposite end faces 189, 191 thereof,and the teeth have generally arcuately spaced apart tips or radiallyinner ends 195 which define, at least in part, a bore 197 extendinggenerally axially through the core between the opposite end facesthereof, respectively. While twenty-six winding slots 165 are disclosedin stator 163, it is contemplated that other stators having more or lesswinding slots, as discussed hereinafter, and also having winding slotsof various other shapes may be utilized within the scope of theinvention so as to meet at least some of the objects thereof.Furthermore, while teeth 193 and tips 195 thereof are illustrated hereinas being generally radially extending or straight, it is contemplatedthat teeth and tips thereof having various other shapes or positions instator 163 could be employed within the scope of the invention so as tomeet at least some of the objects thereof. Thus, as best seen in FIGS.13 and 14, side portions 185 of coils 177, 179, 181 in winding stages171, 173, 175 may be placed or otherwise inserted either manually or bysuitable automatic coil injection equipment (not shown) generally frombore 197 of stator 163 between adjacent ones of teeth 193 and tips 195thereof into winding slots 165, respectively. Since coil side portions185 are arranged within winding slots 165, opposite end turns or endturn portions 199 of coils 177, 179, 181, which integrally connect withopposite side turn portions 185 thereof, are arranged so as to form apair of opposite end turn groupings 201, 203 adjacent opposite end faces189, 191 of stator 163 extending generally about bore 197 radiallyoutwardly thereof, as best seen in FIG. 18.

As best seen in FIG. 14, a slot liner 205 of suitable insulatingmaterial is disposed in each of slots 165 so as to insulate side turnportions 185 of coils 177, 179, 181 disposed in respective ones of theslots from stator 163; however, it is contemplated that other types ofslot lining insulation, such as a resin insulation layer deposited on orotherwise integrally formed with the stator for instance, may beutilized within the scope of the invention so as to meet at least someof the objects thereof. Further, a slot wedge 207 of suitable insulatingmaterial is disposed across each of slots 165, so as to engage adjacentones of teeth 193 at least adjacent tips 195 thereof thereby to containside turn portions 185 of conductor turns 183 against displacement fromthe slots, respectively. Thus, due to the aforementioned windingconfiguration or arrangement of coils 177, 179, 181 of winding stages171, 173, 175, one of opposite side turn portions 185 of the coils ispositioned in a top section 209 of a respective one of slots 165 and theother of the opposite side turn portions of the coils is positioned in abottom section 211 thereof, respectively, with only the exception of thecoil side turn portions which do not share slots, as discussed in detailhereinafter. Albeit not shown, suitable insulation between windingstages 171, 173, 175 including end turn groupings 201, 203 thereof maybe utilized, if desired, within the scope of the invention so as to meetat least some of the objects thereof.

In one form of the invention, coils 177, 179, 181 of the three windingstages 171, 173, 175 are disposed in slots 165 of stator 163 generallyin the aforementioned lapped winding configuration, FIGS. 13-15;however, it is contemplated that not only a greater or lesser number ofwinding stages but also winding stages having different windingconfigurations, such as those illustrated in FIGS. 15A and 15B forinstance, may be employed within the scope of the invention so as tomeet at least some of the objects thereof. Further, it may be noted thateach of coils 177, 179, 181 in each winding stage spans three of teeth193, i.e., coil side turn portions 185 are contained in every fourth oneof slots 165; however, it is contemplated that the coils may span agreater or lesser number of the teeth within the scope of the inventionso as to meet at least some of the objects thereof. In multi-stagewinding arrangement 167, it may be noted that coils 177-1 to 177-3 and177-5 to 177-7 of winding stage 171, coils 179-2, 179-3 and 179-5 to179-7 of winding stage 173, and coils 181-2 to 181-4 and 181-6 to 181-8of winding stage 175 have one of their opposite side turn portions 185sharing a respective one of slots 165 with one of the side turn portionsof the coils in the same winding stage. It may also be noted that coils179-1, 179-5 and 179-2, 179-4 of winding stage 173 have one of side turnportions 185 thereof sharing a respective one of slots 165 with one sideturn portion 185 of coils 177-4, 177-8 and 181-3, 181-5 in windingstages 171, 175, respectively. Further, it may also be noted that coils177-1, 177-5 and 181-4, 181-8 of winding stages 171, 175 each have aside turn portion 185 which does not share a respective one of slots165, respectively.

An alternative multi-stage winding arrangement for stator 163 is shownschematically in one form of the invention in FIG. 15A. In thisalternative winding arrangement 167a, coils 177-1 to 177-8 of windingstage 171 are disposed in the bottom sections 211 of slots 165, coils179-1 to 179-8 of winding stage 173 are disposed in the top sections 209of the slots, and coils 181-1 to 181-8 of winding stage 175 are disposedin the slots between the aforementioned coils in the top and bottomsections of the slots.

Another alternative multi-stage winding arrangement 167b for stator 163is shown schematically in one form of the invention in FIG. 15B.Although alternative winding arrangement 167b is somewhat similar towinding arrangement 167a, it may be noted that coils 177-5 to 177-8 ofwinding stage 171 are shifted to the top sections 209 of slots 165 whilecoils 179-5 to 179-8 of winding stage 173 are shifted to the topsections 211 of the slots for reactance purposes. Of course, coils 181-1to 181-8 of winding stage 175 are disposed in slots 165 between the topand bottom sections 209, 211 thereof.

Referring now to FIGS. 16-18, electronically commutated motor orbrushless DC motor 45 in one form of the invention comprises stationaryassembly 161 with stator 163 thereof disposed within a housing 213, androtatable assembly 151 is arranged in magnetic coupling relation withthe stator and suitably journaled in a pair of opposite end shields 215,217 of the stationary assembly which are secured to the housing,respectively.

More particularly, housing or shell 213 comprises a generally cylindricsleeve 219 which may be formed of any desired material, and the sleevehas a bore 221 extending therethrough between a pair of opposite annularend flanges 223, 225 or the like integrally formed with the sleeve. Aplurality of cooling fins 227 are integrally formed on sleeve 219externally thereof between end flanges 223, 225, and a plurality of ventholes 229 may be provided, if desired, through the sleeve adjacent theend flanges so as to intersect with sleeve bore 221, respectively.Peripheral portion 187 of stator 163 is received within sleeve bore 213being retained therein by suitable means, such as for instance apress-fit or heat shrinking between the peripheral portion of the statorand the sleeve bore. While housing 213 is illustrated for purposes ofdisclosure, it is contemplated that other housings having othercomponent parts different from those illustrated herein may be utilizedwithin the scope of the invention so as to meet the objects thereof.

End shields 215, 217 are secured to housing 213 adjacent opposite endflanges 223, 225 of sleeve 219 by suitable means, such as a plurality ofscrews 231 or the like for instance, respectively. A pair of generallycentrally located bearing openings 233, 235 extend through end shields215, 217, and a pair of bearing means, such as self-lubricating bearings237, 239 for instance, are mounted in the openings respectively. Rotor43 of rotatable assembly 151 is generally coaxially arranged withinstator bore 197 of stationary assembly 161 so as to provide apredetermined air gap 241 therebetween, and shaft extensions 157, 159 ofthe rotatable assembly extend through bearings 237, 239 so as to bejournaled thereby, respectively. Thus, it may be noted that polesections 49,53 of rotor 43 are disposed in magnetic coupling relationwith winding stages 171, 173, 175 in stator 163 which are adapted to becommutated or energized in plurality of preselected sequences and/or aplurality of preselected different sequences, as discussed hereinafter.Albeit not shown, the commutation of winding stages 171, 173, 175 in theaforementioned plurality of preselected sequences and/or plurality ofpreselected different sequences may be effected through the connectionof such winding stages with suitable circuitry, such as for instancethat disclosed in copending applications of Harold B. Harms and David M.Erdman Ser. No. 77,776 filed Sept. 21, 1979 now abandoned, and Ser. No.77,656 filed Sept. 21, 1979, now abandoned, and each of these copendingapplications is incorporated by reference herein.

While stator 163 of electronically commutated motor 45 may have somecharacteristics comparable to those of a conventional A.C. motor, suchas for instance being wound by existing coil winding and placementequipment employed in the manufacture of A.C. motors, it may be notedthat the number of slots 165 employed in stator 163 to accommodatemulti-stage winding arrangement 167 is different than the product of aninteger multiplied by the number of poles in rotatable assembly 151. Inthis vein, an alternative designation of the required number of slots167 in stator 165 may be stated by the following equation:

    s=P(S) (X)±y

where

s=number of slots in stator 165;

P=number of poles in rotatable assembly 151;

S=the number of winding stages;

X=a selected integer greater than zero; and

y=an integer not less than one or greater than two.

Thus, it may be noted that the twenty-six winding slots 165 in stator163 accommodates the three winding stages 171, 173, 175 magneticallycoupled with the eight poles of rotatable assembly 151 so as to satisfythe aforementioned equation, and the number of slots in the stator,i.e., twenty-six slots, is different than the product of an integermultiplied by the eight poles of the rotatable assembly.

In the operation of electronically commutated motor 45 with reference toFIG. 19, it is desirable to provide an advanced timing angle, i.e., anadvancement of the energization of commutation of winding stages 171,173, 175, which is defined as angle α in FIG. 20. In explanation of thistiming angle advancement, zero advancement would occur in electronicallycommutated motor 45 if one of winding stages 171, 173, 175 thereof wouldbe energized at the instant the magnetic center of one of pole sections49, 53 in rotor 43 rotated into a position spaced approximatelytwenty-two and one-half electrical degrees from the axis of one of themagnetic pole established by the energization of such one winding stage.Of course, zero advancement is believed to be the theoretical optimumwith zero winding stage inductance, and energization of theaforementioned one winding stage a preselected number of electricaldegrees before the theoretical optimum position of rotor 43 is attainedcomprises the advancement of commutation, i.e., advanced timing angle α.Of course, the particular advanced timing angle α selected for theoperation of electronically commutated motor 45 may be incorporated intothe aforementioned circuitry of copending applications Ser. No. 77,776filed Sept. 21, 1979, now abandoned in favor of continuation-in-partapplication Ser. No. 141,268 filed Apr. 17, 1980 and Ser. No. 77,656filed Sept. 21, 1979, now abandoned in favor of continuation-in-partapplication Ser. No. 141,267 filed Apr. 17, 1980 which, as previouslymentioned, is operable to effect the switching or energization ofwinding stages 171, 173, 175 in the plurality of preselected sequencesand/or preselected different sequences thereof. In further explanation,the preferred amount of advancement of timing angle α is associated withthe L/R time constant of multi-stage winding arrangement 167. At theaforementioned zero advancement, current in winding stages 171, 173, 175would build up too slowly to achieve maximum possible torque throughoutthe full "on" time. Thus, advancing the commutation angle, as discussedabove, takes advantage of the fact that the generated back emf is lessduring incomplete coupling, i.e., when the polar axii of rotor 43 andthe energized one of winding stages 171, 173, 175 are not in exactalignment; therefore, current build-up time and torque development canbe improved. If the advanced timing angle is too great, currentovershoots may occur thereby to adversely affect efficiency; therefore,the optimum value of the advanced timing angle depends to some extent onthe desired speed at which electronically commutated motor 45 isoperated and the torque desired therefor.

With continued reference to FIG. 19, assume that winding stage 171 ofmulti-stage winding arrangement 167 in electronically commutated motor45 is instantaneously energized, and under this assumption, the centersof the north and south magnetic poles established by winding stage 171have been noted as N171 and S171, respectively. The general location ofthe polar axii or centers of polar sections 49, 53 of rotor 33 aredesignated as S49, N53 and S49 and N53, respectively. If winding stages171, 173, 175 were commutated with the aforementioned zero advancementin a preselected sequence thereof, the N, S poles associated withrespective ones of the winding stages will appear and disappear as thewinding stages are energized and de-energized in the preselectedsequence thereof. Thus, as may be noted from FIG. 19, when the center ofthe magnetic poles S49, N53 of rotor 43 are positioned twenty-two andone-half electrical degrees past a like one of stator poles N171, S171,theoretically winding stage 171 should be energized at the instant so asto establish the poles N171, S171, and winding stage 171 should remainenergized during the subsequent one hundred thirty-five electricaldegrees rotation of the rotor. Then, winding stage 171 would bede-energized. The next one of winding stages 173, 175 in the preselectedsequence would be similarly energized. However, instead of commutatingwinding stages 171, 173, 175 with zero advancement in the preselectedsequence thereof, as discussed above, it is preferred to effect theoperation of electronically commutated motor 45 so that winding stages171, 173, 175 thereof are commutated in advance of the theoreticalcommutation point or angle (i.e., zero advancement) by the predeterminedadvanced timing angle α (in electrical degrees).

In the light of the foregoing discussion, the commutation orenergization of winding stages 171, 173, 175 in the preselected sequencethereof effects the magnetic coupling therewith of rotatable assembly151 causing unidirectional rotation of the rotatable assembly in theclockwise direction, as indicated by the directional arrow in FIG. 19,with respect to stator 163. It may be noted that if winding stages 171,173, 175 were so energized in a preselected sequence reverse to thatdiscussed above, the magnetic coupling of the winding stages withrotatable assembly 151 would cause a reverse unidirectional rotationthereof in the counterclockwise direction with respect to stator 163.Further, it may also be noted that the rotational speed of rotatableassembly during the unidirectional rotation thereof in both theclockwise and counterclockwise directions may be varied by varying atleast the frequency at which winding stages 171, 173, 175 are commutatedin the preselected sequence thereof. In addition, it may be furthernoted that winding stages 171, 173, 175 may be commutated or energizedin pre-selected different sequences effecting the magnetic couplingtherewith of rotatable assembly 151 so as to cause oscillation of therotatable assembly in both the clockwise and counterclockwise directionwith respect to stator 163. The speed of such rotatable assemblyoscillation may be varied in the same manner as discussed above, and theamplitude of such rotatable assembly oscillation may be varied byvarying the successive energization of the winding stages 171, 173, 175during the preselected different sequences of energization thereof. Forinstance, in determining the frequency of the amplitude for theoscillation of rotatable assembly 151, it is contemplated that windingstages 171, 173, 175 could be commutated so that the rotatable assemblyacts as a generator. In other words, when winding stages 171, 173, 175are so commutated, rotatable assembly 151 then generates a voltage whichis induced into the winding stages creating a back emf thereby to effectthe termination of the oscillation movement of the rotatable assemblygenerally at the preselected amplitude of such oscillation movement. Ofcourse, the unidirectional rotation of rotatable assembly 151 may, ifdesired, also be terminated by shorting out winding stages 171, 173, 175so that the rotatable assembly acts as a generator, or if desired, thewinding stages may merely be de-energized.

FIG. 20 is a graphical representation of voltage of one winding stage,such as winding stage 171 for instance, developed by electronicallycommutated motor 45. The solid trapezoidal curve illustrates theinstantaneous voltage in winding stage 171 for a revolution through onepair of adjacent pole sections 49,53 in rotor 43. The dashed trapezoidalcurves are similarly shown for winding stages 173 and 175 to representtheir respective instantaneous voltage contributions. The heavy solidcurve displays the net affect of winding stage 171 being energized forone hundred thirty-five electrical degrees only with winding stage 175being energized for one hundred thirty-five electrical degrees and so onfor winding stage 175. If a more detailed discussion is desired withrespect to the commutation of winding stages 171, 173, 175 to effect theoperation of electronically commutated motor 45, reference may be had tothe aforementioned U.S. Pat. No. 4,005,347.

With reference again in general to the drawings, a transmissionmechanism 245, which is adapted to be employed in a laundry or clotheswashing machine 247, is shown having a housing or casing 249 with a pairof opposite end portions or walls 251, 253 (FIGS. 21-26). Input means255 extending through opposite end portion or wall 251 of casing 249 isoperable for rotation so as to oscillate in one operating mode oftransmission mechanism 245 and also for rotation unidirectionally inanother operating mode of the transmission mechanism (FIG. 21). A pairof generally coaxially arranged output means 257, 259 extending throughopposite end portion or wall 253 of casing 249 are operable generallyfor conjoint rotation with input means 255 during the one and anotheroperating modes of transmission mechanism 245, respectively (FIGS. 23and 24). Means, indicated generally at 261, is disposed in casing 249for transmitting to output means 257 the rotation of input means 255during the aforementioned one operating mode while output means 259 isat rest and for transmitting to output means 259 the rotation of theinput means during the aforementioned another operating mode whileoutput means 257 is at rest, respectively.

More particularly and with specific reference to FIGS. 21-24, casing orcover 249 of transmission mechanism 245 encases a bearing support orhousing indicated generally at 263, disposed within a chamber 265 of thecasing. Bearing support 263 includes a pair of cylindric sidewalls 267,269 with cylindric sidewall 267 being seated on casing end wall 251. Anintermediate support wall or plate 271 is interconnected betweencylindric sidewalls 267, 269, and an upper support wall or plate 273 isconnected to the upper end of cylindric sidewall 269 generally adjacentend wall 253 of casing 249. A plurality of mounting openings 275 may beprovided in casing 249 so as to mount transmission mechanism 245 inlaundry machine 247, as discussed hereinafter. Opposite end walls 251,253 have a pair of openings 277, 279 extending therethrough so as tointersect with chamber 265, and a pair of bearing means 281, 283 aresupported in the openings in journaling engagement with input means 255and output means 257, respectively. If desired, a plurality of mountingstuds 285 may be integrally or otherwise provided on lower end wall 251so as to extend therefrom for receiving electronically commutated motor45 when transmission mechanism 245 is mounted in laundry machine 247, asdiscussed hereinafter.

Input means 255 includes an input shaft 287 journaled in bearing means281 and extending through opening 277 in end wall 251 with a free end orend portion 289 disposed generally adjacent end wall 251 within chamber265. An input or pinion gear 291 within chamber 265 is carried on freeend 289 of input shaft 287 so as to be conjointly rotatable therewith,and the input shaft is adapted to be rotated or driven unidirectionallyand also so as to oscillate in opposite directions.

Output means 257 includes a tubular output shaft 293 having a generallyaxial bore 295 therethrough, and the tubular output shaft extendsthrough opening 279 in casing end wall 253. Output shaft 293 isjournaled in bearing means 283 in casing end wall 253 and extendsthrough support wall 273 so that a lower interior or free end of theoutput shaft is journaled in another bearing means 297 disposed inanother opening 299 extending through intermediate support 271. Anoutput, driven or pinion gear 301 is carried about tubular shaft 293 soas to be conjointly rotatable therewith, and the output gear is arrangedso as to extend from the tubular shaft generally in spaced relationbetween supports 271, 273.

Output means 259 includes an output shaft 303 which extends generallycoaxially through bore 295 of tubular shaft 293, and output shaft 303has an exterior or free end or end portion 305 exteriorly of chamber 265with an opposite interior free end or end portion 307 within thechamber, Albiet not shown, interior end 307 of output shaft 303 isjournaled in a bearing means provided therefor in casing end wall 251,and exterior end 305 of output shaft 307 may be journaled in suitablebearing means (not shown) provided therefor. Another output, driven orpinion gear 309 is carried by output shaft 303 generally adjacentinterior end 307 thereof so as to be spaced between casing end wall 251and support wall 271 within chamber 265.

Transmitting means 261 is provided for transmitting the rotationalmovement of input shaft and gear 287,291 to tubular output shaft andgear 293, 301 and to output shaft and gear 303, 309, respectively.Transmitting means 261 includes means, such as a driving or idler shaft311 and a pinion gear 313 carried thereon, associated in coupledrelation with output shaft and gear 303, 309 for driving it, and means,such as a driven or idler shaft 315 and a pinion gear 317 carriedthereon, associated in coupled relation with input shaft and gear287,291 for being driven by it. Driving and driven means or idler shafts311, 315 each have a pair of opposite end portions 319,321 and 323, 325journaled in a pair of bearing means 327 329 and 331, 333 with bearingmeans 327, 331 being disposed in casing end wall 251 and bearing means329 333 being disposed in upper support wall 273, respectively. Drivenidler shaft 315 has a plurality of splines 335 extending axiallythereabout between opposite ends 323, 325 of the driven idler shaft, andpinion gear 317 is carried on the driven idler shaft generally adjacentlower opposite end 323 thereof in meshing engagement with input gear291. Thus, the mesh between input gear 291 and pinion gear 317 effectsthe concerted driven rotation of idler shaft 315 with input shaft 287.Pinion gear 313 is carried on driving idler shaft 311 so as to bearranged in meshing engagement with output gear 309 on output shaft 303,and therefor the meshing engagement between pinion gear 313 and outputgear 309 effects the conjoint driven rotation of output shaft 303 withthe driving idler shaft, as discussed hereinafter. Another pinion gear337 is also carried on idler shaft 311 generally in spaced relation withpinion gear 313 thereon.

Transmitting means 261 also includes means, such as a pair ofinterconnected stepped shifting gears 339, 341 selectively movablebetween a plurality of shifted positions with respect to idler shafts311, 315 and operable generally in one of the shifted positions (as bestseen in FIG. 21) for coupling idler shaft 315 with tubular output shaft293 and in another of the shifted positions thereof (as best seen inFIG. 22) for coupling idler shaft 315 with idler shaft 311. A splinedbore 343 is coaxially provided through coupling means or steppedshifting gears 339, 341, and splines 335 on idler shaft 315 arecooperatively receiving in the splined bore so that the stepped shiftinggears are axially movable between at least the upper shifted or spinposition and the lower shifted or agitating position thereof on idlershaft 315. As discussed hereinafter, stepped shifting gears 339, 341 mayalso be provided with a third shifted position, such as a neutral orpump operating position, disengaged from output shafts 293, 303. Thus,through the engagement of splines 335 on idler shaft 315 with splinedbore 343 of stepped shifting gears 339, 341, the stepped shifting gearsare not only axially movable or shiftable on idler shaft 315 but alsoconjointly rotatable therewith in response to the rotation of inputshaft 287. Larger stepped shifting gear 341 is arranged in meshingengagement with output gear 301 on tubular output shaft 293 when steppedshifting gears 339, 341 are in the upper shifted position thereof, andsmaller shifting gear 339 is arranged in meshing engagement withintermediate pinion gear 337 on idler shaft 311 when the steppedshifting gears are in the lower shifted position thereof. To completethe description of transmission mechanism 245, a shift actuating device,schematically shown and indicated generally at 345, is selectivelyoperable for moving a linkage 347 thereof to effect the shifting axialmovement of stepped shifting gears 339, 341 connected with the leakagebetween the shifted positions of the stepped shifting gears on idlershaft 315; however, while the shift actuating device and linkage areillustrated herein in association with stepped shifting gears 339, 341,for purposes of disclosure, it is contemplated that other means may beemployed for effecting the shifting of the stepped shifting gearsbetween the shifted positions thereof, i.e., shifting transmissionmechanism 245 between its aforementioned operating modes, within thescope of the invention so as to meet at least some of the objectsthereof.

With respect to the operation of transmission device 245, it will berecalled that input shaft 287 may be driven or operated so as to beoscillatable in one operating mode of the transmission mechanism andunidirectionally rotated in another operating mode of the transmissionmechanism. When input shaft 287 is unidirectionally rotated, linkage 347is actuated by shifting device 345 so that stepped shifting gears 339.341 are in the upper shifted position thereof (as best seen in FIG. 21)wherein larger stepped shifting gear 341 is meshed with output gear 301of tubular output shaft 293. In this manner, unidirectional rotation ofinput shaft 287 is transmitted through meshed input gear 291 and piniongear 317 to idler shaft 315 to effect the conjoint unidirectionalrotation thereof with the input shaft. Since splines 335 on idler shaft315 are received in splined bore 383 of stepped shifting gears 339,341,the stepped shifting gears are conjointly unidirectionally rotated withidler shaft 315, and this conjoint unidirectional rotation of theshifting gears is transmitted through meshed larger stepped shiftinggear 341 to output gear 301 on tubular output shaft 293 so as to effectthe conjoint unidirectional rotation thereof with the stepped shiftinggears. Thus, in the one operating mode of transmission mechanism 245 asdetermined by shifting device 345, the unidirectional rotation of inputshaft 287 is transmitted to tubular output shaft 293 effecting theconjoint unidirectional rotation thereof with the input shaft whileoutput shaft 303 remains at rest.

When linkage 347 is actuated by shifting device 345 so as to axiallymove stepped shifting gears 339, 341 downwardly toward its lower shiftedposition on idler shaft 315 (as best seen in FIG. 22), larger steppedshifting gear 341 is disengaged from output gear 301 on tubular outputshaft 293, and smaller stepped shifting gear 339 is moved into meshingengagement with intermediate pinion gear 337 on idler shaft 311. Withstepped shifting gears 339, 341 in their lower shifted position,transmission mechanism 245 may function in its another operating modewith input shaft 287 being oscillatally rotatable. Thus, the oscillationof input shaft 287 is transmitted through meshed input gear 291 andpinion gear 317 to idler shaft 315 to effect the conjoint oscillationthereof with the input shaft. Since splined bore 343 of stepped shiftinggears 339, 341, is received on splines 335 of idler shaft 315, thestepped shifting gears are conjointly oscillated with idler shaft 315,and such conjoint oscillation is transmitted to idler shaft 311 throughthe meshing engagement of smaller stepped shifting gear 339 withintermediate gear 337 on idler shaft 311. This conjoint oscillation ofidler shaft 311 with idler shaft 315 is transmitted to output shaft 303through the meshing engagement of pinion gear 313 on idler shaft 311with output gear 309 on output shaft 303. Thus, the oscillation of inputshaft 287 is transmitted to output shaft 303 during the anotheroperating mode of transmission mechanism 345.

In the foregoing descripion of transmission mechanism 245, casing 249may contain a suitable lubricant (not shown) for lubricating thecomponents and bearing means thereof; however, it is contemplated thatat least the various gears of such components may be formed from a resinmaterial within the scope of the invention so as to meet at least someof the objects thereof, and if so, then the casing and the lubricant maybe omitted, and such bearing means may be of the self-lubricated type.

With reference again to the drawings in general and recapitulating atleast in part with respect to the foregoing, laundry or clothes washingmachine 247 has a cabinet 351, and means, such as a perforate spin tub353 or the like for instance, arranged within the cabinet for receivingwater and clothes (not shown) to be laundered therein is adapted to beunidirectionally rotatable at a velocity great enough to centrifugallydisplace at least some of the water from the clothes to be launderedtherein (FIG. 25). Means, such as an agitator 355 or the like forinstance, arranged within receiving means or spin tub 353 so as to begenerally coaxial therewith is adapted to be oscillated, i.e., rotatedin opposite directions, for agitating the clothes in the water to effectthe laundering thereof (FIG. 25). Electronically commutated motor 45mounted within cabinet 351 has stationary assembly 163 with windingstages 171, 173, 175 wound therein and adapted to be commutated so as tobe excited or energized in at least one preselected sequence and in atleast one of preselected different sequences (FIGS. 16-19, 25 and 26).Rotatable assembly 151 is arranged with stationary assembly 163 inmagnetic coupling relation with winding stages 171, 173, 175, and therotatable assembly is oscillated upon the energization of the windingstages in the at least one preselected different sequences and alsounidirectionally rotated upon the energization of the winding stages inthe at least one preselected sequence (FIGS. 16-19, 25 and 26).Transmission mechanism 245 is adapted to be operatively connected witheach of spin tub 353 and agitating means or agitator 355 fortransmitting the oscillation movement of rotatable assembly 165 to theagitator so as to effect the conjoint oscillation movement thereof withthe rotatable assembly and for transmitting the unidirectional rotationof the rotatable assembly to the spin tub so as to effect the conjointunidirectional rotation thereof with the rotatable assembly,respectively (FIGS. 21-26). Input shaft 287 of transmission mechanism245 is constituted by shaft 155 of rotatable assembly 151 (FIG. 25).

More particularly and with specific reference to FIGS. 25 and 26,cabinet 351 of laundry machine 247 has a base 357 with a plurality ofadjustable or leveling support feet 359 thereon. An outer or uppercabinet structure 361 has the lower end portion thereof supported on orotherwise connected to base 357 by suitable means, and the upper endportion of the upper cabinet structure support or is otherwise connectedwith a cover 363 therefor. Sealing means, such as a resilient gasket 365or the like for instance, is sealably fitted or otherwise interposedbetween the upper end portion of cabinet structure 361 and cover 363.

Laundry machine 247 is provided with a supporting frame 367 on whichtransmission mechanism 245, electronically commutated motor 45, a pumpdevice 369 for the laundry machine, spin tub 353 and agitator 355 aresupported generally in vertically aligned or in-line relation, asdiscussed hereinafter. Frame 367 is suspended or otherwise mountedwithin cabinet 351 on a plurality of brackets 371 suitably attached tobase 357 by a plurality of damping means 373; however, for the sake ofdrawing simplicity only one of such bracket and damping means is shownin FIG. 25. Each vibration damping means 373 has resilient means, suchas a coil spring 375 or the like for instance, biased or otherwiseinterconnected between bracket 371 and frame 367, and other resilientmeans, such as a generally U-shaped spring clamp 377 or the like forinstance, is secured to the bracket having a pair of dependingprestressed legs 379 straddling a part 381 of the frame in grippingengagement therewith with resilient friction pads 383 interposed betweenthe legs and the frame part, respectively. Thus, vibration damping means373 acts not only to limit or damp twisting or torquing movement butalso vertical movement of frame 367 which may be imparted theretoparticularly during the spin cycle or operating mode of laundry machine247, as discussed hereinafter.

A platform or other upstanding structure 385 is generally centrallyprovided on frame 367 and integrally connected thereto by suitable means(not shown), and lower end wall 251 on casing 249 of transmissionmechanism 245 is seated on an upper free end or seat 287 of the platformbeing connected thereto by suitable means, such as a plurality of nutsand bolts 389 or the like for instance, arranged with mounting openings275 in the lower end wall and aligned mounting openings 391 in theplatform as best seen in FIG. 26. Further with respect to FIG. 26, itmay be seen that end shield 215 of electronically commutated motor 45 isremoved from housing 213 thereof, and flange 223 of housing sleeve 219is abutted against lower end wall 251 of transmission mechanism casing249 being secured by suitable means, such as a plurality of nuts 393 orthe like for instance, threadedly received on stud plurality 285extending from the lower end wall. Thus with electronically commutatedmotor 45 mounted to transmission mechanism 245 so as to depend therefromthrough platform 385 toward frame 367, shaft extension 157 on rotatableassembly shaft 151 in electronically commutated motor 45 is journaled inbearing means 281 disposed in lower end wall 251 of transmissionmechanism casing 249 so as to constitute input shaft 287 of thetransmission mechanism, and of course, input gear 291 is mounted on thefree end of shaft extension 157 so as to be conjointly rotatable withrotatable assembly 151 of the electronically commutated motor upon theenergization thereof. The other end shield 217 of electronicallycommutated motor 45 may also be removed so that flange 225 of housingsleeve 219 is abutted against pump 369, and the other shaft extension159 of rotatable assembly 151 extends into driving engagement with thepump of laundry machine 247. Pump 369 is secured to flange 225 ofelectronically commutated motor 45 by suitable means, such as aplurality of nuts 395 or the like for instance, threadedly received on astud plurality 397 extending from the pump. While the aforementionedmounting arrangements or interconnections of transmission mechanism 245to platform 385, electronically commutated motor 45 to the transmissionmechanism, and pump 369 to the electronically commutated motor have beenillustrated herein for the purposes of disclosure, it is contemplatedthat various other mounting arrangements or interconnections may be madebetween such components of laundry machine 247 within the scope of theinvention so as to meet at least some of the objects thereof.

With reference again to FIG. 25, spin tub 353 includes a generallyannular perforate sidewall 399 having a base wall 401 integrallyinterconnected therewith, and a generally central opening 403 extendsthrough the base wall. Means, such as a collar 405 or the like forinstance, is provided for securing spin tub 353 to tubular output shaft293 of transmission mechanism 245, and the securing means or collarextends through opening 403 in spin tub base wall 401 being grippinglyand sealably engaged with the opposite sides thereof generally about theopening. Albeit not shown, the tubular output shaft 293 extendingexteriorly of transmission mechanism casing 249 is connected by suitablemeans with collar 405 so that spin tub 353 is conjointlyunindirectionally rotatable with the tubular output shaft during thespin cycle of laundry machine 247, as discussed hereinafter. Furtherupper end 305 of output shaft 303, which extends exteriorly oftransmission mechanism casing 249 and coaxially through tubular outputshaft 293, is connected by suitable means (not shown) with agitator 355so that the agitator is conjointly oscillated with output shaft 303during the agitation cycle or operating mode of laundry machine 247, asalso discussed hereinafter.

An intermediate or enclosing tub 407 is provided with a sidewall 409spaced generally between spin tub sidewall 399 and upper cabinetstructure 361, and a base wall 411 is integrally formed with theenclosing tub sidewall having a generally centrally located openingtherethrough defined by an integral generally annular flange 413depending from the base wall in spaced relation generally adjacentcasing 249 of transmission mechanism 245. Sealing means, such as aresilient annular boot 415 or the like for instance, is sealablyinterconnected or otherwise interposed between flange 413 on enclosingtub 407 and casing 249 of transmission mechanism 245, and anothergenerally annular flange 417 integrally formed on enclosing tub sidewall409 about the free or upper end thereof extends into supportingengagement with the upper end portion of upper cabinet structure 361 andsealing engagement with gasket 365 extending thereabout. To complete thedescription of laundry machine 247, conduit means, such as a hose 419 orother flexible connection for instance is connected between base wall411 of enclosing tub 407 and pump 369 providing a passage for theremoval from the enclosing tub of water selectively discharged into spintub 353 through a nozzle 421.

In the operation of laundry machine 247, assume that stepped shiftinggears 339, 341 in transmission mechanism 245 are disposed in the lowershifted or agitation position thereof with smaller stepped shifting gear339 driving output shaft 303 through the meshing engagement of thesmaller shifting gear with intermediate gear 337 on idler shaft 311 andthe meshing engagement of pinion gear 313 thereon with output gear 309on the output shaft, as discussed hereinabove with respect to FIGS.21-24. With transmission mechanism 245 so set or shifted to effect theagitation cycle or operating mode of laundry machine 247, water may beintroduced through nozzle 421 into spin tub 353 so that it flows throughthe perforations therein into enclosing tub 407, and clothes to belaundered in the water and a charge of detergent or the like (not shown)may also be placed in the spin tub. Of course, the level to which thewater rises in enclosing tub 407 may be controlled by any suitable fluidlevel sensing means, as well known in the art. With this preparation,electronically commutated motor 45 may be energized to commence the washor agitation cycle of laundry machine 247. Upon the energization ofelectronically commutated motor 45, winding stages 171, 173, 175 of theelectronically commuted motor are commutated so as to be excited in theaforementioned preselected different sequences which effects themagnetic coupling therewith of rotatable assembly 151 so as to impartoscillating movement or rotation to the rotatable assembly. Of course,as previously mentioned, this oscillating rotation of rotatable assembly151 may be of any desired or preselected speed depending upon thefrequency of the commutation of winding stages 171, 173, 175 and also ofany desired or preselected amplitude depending upon the time or numberof cycles the frequency is applied to the winding stages. Theoscillating rotation of rotatable assembly 151 is translated ortransmitted by transmission mechanism 245 to its output shaft 303 whichis drivingly connected or otherwise associated with agitator 355 so asto effect the conjoint oscillation thereof with the rotatable assemblyof electronically commutated motor 45. In this manner, the oscillatorymovement of agitator 355 within spin tub 353 effects the agitation andlaundering of the clothes therein. Albeit not shown for purposes ofbrevity, pump 369 may include means for pumping water from enclosing tub407 through a filter back into spin tub 353 in order to trap or filterout much of the lint which may be separated from the clothes as they arelaundered during the above discussed agitation cycle of laundry machine247. After laundry machine 247 has been operated for a desired orpreselected period of time in its agitation cycle, electronicallycommutated motor 45 may be de-energized so as to terminate suchagitation cycle.

Subsequent to the agitation cycle of laundry machine 247 and in order toinitiate the spin cycle thereof, shifting device 345 for transmissionmechanism 245 may be actuated causing its linkage 347 to move steppedshifting gears 339, 341 upwardly on idler shaft 315 toward the spin orupper shifted position thereof, as shown in FIG. 21, so that largerstepped shifting gear 341 is meshed with output gear 301 on tubularoutput shaft 293. At this time, electronically commutated motor 45 maybe reenergized with its winding stages 171, 173, 175 commutated so as tobe excited in a preselected sequence which effects the magnetic couplingtherewith of rotatable assembly 151 in the manner discussed hereinbeforeto impart unidirectional rotation to the rotatable assembly. Aspreviously mentioned, the unidirectional speed of rotatable assembly 151may be of any desired or preselected speed depending upon the frequencywith which winding stages 171, 173, 175 of electronically commutatedmotor 45 are commutated in the preselected sequence during the spincycle of laundry machine 247; however, it is contemplated that the speedof the unidirectional rotation of the rotatable assembly will beappreciably greater than the speed of the above discussed oscillationrotation of the rotatable assembly. With stepped shifting gears 339,341, moved into the upper shifted position thereof in transmissionmechanism 245, as discussed above, the unidirectional rotation ofrotatable assembly 151 is translated or transmitted by the transmissionmechanism to its tubular output shaft 293 which is drivingly connectedor otherwise associated with spin tub 353 so as to effect the conjointunidirectional rotation thereof with the rotatable assembly ofelectronically commutated motor 45. In this manner, the unidirectionalrotation of spin tub 353 is operative to effect the centrifugaldisplacement of water from the clothes within the spin tub, and ofcourse, pump 369 may, if desired, be arranged to be driven byelectronically commutated motor 45, as discussed hereinafter, andincludes means for effecting the removal of water from the spin tub andenclosing tub 407 through hose 419 to a drain (not shown). After laundrymachine 247 has been operated for a desired or preselected period oftime in its spin cycle, electronically commutated motor 45 may bede-energized so as to terminate such spin operating mode.

To complete the operation of laundry machine 247, shifting device 345may be selectively actuated to operate linkage 347 and move steppedshifting gears 339, 341 to the neutral position thereof, as previouslymentioned, to effect a pumping cycle or mode of operation of the laundrymachine. In their neutral position, stepped shifting gears 339, 341 aredisengaged from output gear 301 on tubular output shaft 293 and fromintermediate gear 337 on idler shaft 311 which is drivingly connectedwith through its gear 313 with output gear 309 on output shaft 303.Therefor, with stepped shifting gears 339, 341 in their neutralposition, electronically commutated motor 45 may be energized to drivepump 369 while being, in effect, drivingly disconnected from spin tub353 and agitator 355 by transmission mechanism 245.

It will be understood that while the above description of laundrymachine 247 does not illustrate all of the valving and particularcontrols normally provided on modern domestic laundry machines, theomission and/or simplification of these components is primarily for thepurposes of brevity; however, it is contemplated that such componentsmay be provided in the laundry machine and that such laundry machine maybe provided with other operating modes or cycles within the scope of theinvention so as to meet at least some of the objects thereof.

With reference again in general to the drawings and recapitulating withrespect to the foregoing, it may be noted that a drive is provided forlaundry machine 247 (FIGS. 13-20 and 21-26). In this drive, transmissionmechanism 245 has input means 255 adapted for both oscillating andunidirectional rotation, and coaxially arranged output means 257, 259 ofthe transmission mechanism are adapted for selective driven connectionwith the input means so as to be conjointly rotatable therewith,respectively (FIGS. 21-26). Electronically commutated motor 45 isassociated in mounting relation with transmission mechanism 245 andincludes rotatable assembly 151 connected generally in aligned anddirect driving relation with the transmission so as to comprise theinput means 255 thereof (FIGS. 25 and 26). Electronically commutatedmotor 45 further includes multi-stage winding arrangement 167 with eachwinding state 171, 173, 175 thereof being selectively energizable toeffect both oscillation and unidirectional rotation of rotatableassembly 151 thereof (FIGS. 13-20).

Referring now to FIGS. 27 and 28, alternative pole sections 53a and 53bare shown assembled in rotor 43 by generally the same method of makingthe rotor as discussed hereinabove and having generally the samecomponent parts functioning in generally the same manner as thepreviously discussed pole section 53 with the following exceptions;however, while pole sections 53a and 53b may meet at least some of theobjects set out hereinabove, it is believed that pole sections 53a and53b also have indigenous objects and advantageous features which will bein part apparent and in part pointed out in the following discussion.

In pole sections 53a of FIG. 27, a generally T-shaped opening 431 isprovided therethrough in which hardenable material 93 is received andsolidified when provided in slots 99 of rotor 43 or otherwise introducedthereinto, as previously discussed with respect to the method of makingthe rotor and as indicated in functional diagram box 133 of FIG. 2.Thus, the abutment of hardenable material 93 with flanges 141, 143 ofpole sections 49 and the coaction of the hardenable material withT-shaped opening 431 in pole sections 53a serves to retain both the polesections 53a and magnets 89, 91 against displacement from thepreselected or located positions thereof within rotor slots 99. It maybe noted that seats 83, 85 provided on the previously discussed polesection 53 for seating abutment with magnets 89, 91 may be omitted frompole section 53a due to the retaining relationship of T-shaped opening431 thereof with hardenable material 93 in rotor slots 99. WhileT-shaped opening 431 in pole section 53a is shown for purposes ofdisclosure, it is contemplated that other shaped openings may beprovided in other pole sections for the retaining relationship withhardenable material 93 in rotor slots 99 within the scope of theinvention so as to meet at least some of the objects thereof. Of course,one of those contemplated openings is shown at 433 in pole section 53bof FIG. 28. In opening 433, opposed serrations 435, 437 are provided onpole sections 53b in generally the same retaining relation withhardenable material 93 in rotor slots 99 as discussed above with respectto pole sections 53a.

Referring now to FIGS. 29-32, there is disclosed an alternativerotatable assembly 451 in one form of the invention for use inelectronically commutated motor 45 and also an alternative method ofmaking, manufacturing or assembling a core or rotor 453 which may beutilized in the rotatable assembly. This alternative method androtatable assembly 451 utilizes generally the same component partsarranged so as to function generally in the same manner as thepreviously discussed method and rotatable assembly 151 with theexceptions discussed hereinafter; however, while this alternative methodand rotatable assembly 451 may meet at least some of the objects set outhereinabove, it is believed that the alternative method and rotatableassembly 451 also have respective indigenous objects and advantageousfeatures which will be in part apparent and in part pointed out in thefollowing discussion.

With reference to FIGS. 29 and 30, rotor 453 includes a stack 455 oflaminations 457 arranged generally in juxtaposed or face-to-facerelation in a desired stack length or height. Each lamination 457 has aunitary body 459 of generally thin ferromagnetic material, and a pair ofradially spaced outer and inner peripheral edges 461, 463 are providedon the body with the inner peripheral edge defining a shaft receivingopening. A plurality of openings, such as generally U-shaped or V-shapedapertures or slots 465 for instance, are provided through body 459intersecting with outer peripheral edge 461, and the openings arearranged with each other in generally arcuate spaced relation about thebody. Thus, a plurality of pole sections 467 are respectively defined onbody 459 between adjacent ones of openings 465 so as to extend betweenouter and inner peripheral edges 461, 463, and a plurality of means,such as inner peripheral bridges or connecting arms 469 for instance, onthe body are interposed or otherwise integrally interconnected betweenadjacent ones of pole sections 467 for bridging therebetween generallyadjacent the inner peripheral edge.

As previously mentioned, each of openings 465 intersect with outerperipheral edge 461, and the openings include a pair of opposed sideedges 471, 473 extending generally in converging relation with respectto each other between outer and inner peripheral edges 461, 463 with anend edge 175 interconnected between the opposed side edges and spacedgenerally adjacent the inner peripheral edge. Thus, bridges 469 aredefined on body 459 generally between end edge 475 of openings 465 andinner peripheral edge 463, and pole sections 467 are defined on the bodygenerally between opposite ones of side edges 471, 473 or adjacentopenings 465, respectively. A pair of opposed extensions or flanges 477,479 are integrally provided on adjacent ones of pole sections 467 atleast adjacent outer peripheral edge 461 and the flanges extend intoopenings 465 past opposed side edges 471, 473 thereof. While openings465 are described herein as being generally V-shaped, it is contemplatedthat other openings having various other shapes may be employed in otherlaminations within the scope of the invention so as to meet at leastsome of the objects thereof.

A plurality of other pole sections 481 may be formed from generally thesame ferromagnetic material as that of lamination body 459, and each ofpole sections 481 is generally V-shaped so as to generally correspond toor fit within openings 465, as discussed in greater detail hereinafter.Pole sections 481 include a generally arcuate edge 483 formed so as tohave generally the same radius of curvature as outer peripheral edge 461on lamination body 459, and the arcuate edge interconnects between oneof the ends a pair of opposite side edges 485, 487 on pole section 481,respectively. Opposite side edges 485, 487 extend generally convergentlyfrom arcuate edge 483, and the other of the ends of the opposite sideedges are interconnected with free end edge 489 which is generallyopposite arcuate edge 483. To complete the description of laminations457 and pole sections 477, a plurality of amortisseur winding receivingapertures 491 are provided through the laminations and the polesections.

With reference in general to FIGS. 29-32 and recapitulating at least inpart with respect to the foregoing, there is illustrated a method ofmaking, manufacturing or assembling rotor 453, and the rotor has aplurality of discrete polar regions or areas, such as generally definedby pole sections 467 for instance, with such polar regions or polesections being spaced apart generally about a peripheral portion 493 ofthe rotor (FIGS. 29, 30 and 32). In this method, a plurality of otherdiscrete polar regions or areas, such as defined by pole sections 481for instance, are positioned or otherwise placed or located inpreselected positions between adjacent ones of pole sections 467, and aplurality of sets of magnetic material elements, such as magnets 89, 91for instance are disposed or otherwise arranged between pole sections481 and the pole section 477 adjacent thereto, respectively (FIGS. 30and 32). A hardenable nonmagnetic material 495 is solidified in place inrotor 453 between pole sections 467, 481 and magnets 89, 91 so as notonly to effect magnetic polarity definition between pole sections 467and pole sections 481 but also to retain pole sections 481 againstdisplacement from the preselected positions thereof, respectively (FIG.33). While hardenable non-magnetic material 495 as discussed above isdisclosed as a resin material, it is contemplated that other hardenablenon-magnetic materials, such as aluminum, copper or alloys thereof forinstance, may be employed in the method of making rotor 453 within thescope of the invention so as to meet at least some of the objectsthereof.

More particularly and with specific reference to FIGS. 29-32, aplurality of laminations 457 are stacked or otherwise assembled togethergenerally in juxtaposed or face-to-face relations thereby to formlamination stack 455, as shown in FIG. 29, and such stacking of thelaminations is illustrated by functional diagram box 497 in FIG. 31.Either during or subsequent to the above discussed stacking oflaminations 457 into rotor stack 455, openings 465 and apertures 491 ofeach of the laminations are respectively aligned or otherwise arrangedor located with respect to each other so that such aligned openingsdefine a plurality of slots or slot openings 499 and so that suchaligned apertures define a plurality of amortisseur winding receivingopening or bores 501 which extend across or through rotor stack 455between a pair of opposite ends or end faces 503, 505 thereof,respectively. Even though the alignment of openings 465 and apertures491 so as to respectively form slots 499 and bores 501 may beaccomplished during the stacking of laminations 457, as discussed above,such alignment is illustrated in a separate functional diagram box 507in FIG. 31 for purposes of clarity. Further, albeit not shown for thesake of brevity, it is understood that suitable equipment may beemployed to effect the stacking of laminations 457 and the alignment ofopenings 465 and apertures 491, as discussed above. Of course, it mayalso be noted that upon the alignment of openings 465 and apertures 491,outer and inner peripheral edges 461, 463 of laminations 457 in stack455 thereof are also generally aligned or otherwise arranged with eachother so that the outer peripheral edges define in part peripheralportion or wall 493 on rotor 453 between opposite ends 503, 505 therofand inner peripheral edges 463 generally define a shaft receiving bore509 extending through the rotor between the opposite end thereof,respectively, as best seen in FIG. 29. The particular edges onlaminations 457 which define openings 465 therethrough, as discussedabove, are also disposed generally in alignment with each other upon thealignment of the openings so as to form slots 499 in rotor stack 455,and such particular edges in their aligned formation define walls orwall means of the slots; however, for the sake of brevity, such slotwalls will be designated by the reference numerals of such particularedges corresponding thereto when referred to hereinafter.

Either before, after or simultaneously with the above discussed stackingof laminations 457 and the alignment of openings 465 so as to definerotor slots 499, a plurality of pole sections 481 may also be stacked orotherwise assembled together generally in juxtaposed or face-to-facerelations thereby to form a plurality of stacks 511 thereof, as bestseen in FIGS. 29 and 32, with the pole section stacks having generallythe same stack lengths or heights as lamination stack 455. Of course,either during such stacking of pole sections 481 or subsequent thereto,the particular edges on the pole sections are respectively aligned witheach other so as to define walls or wall means on the pole section stack511; however, for the sake of brevity, such pole section walls will bedesignated by the reference numerals of such particular edgescorresponding thereto when referred to hereinafter. When the particularedges of pole sections 481 are so aligned, apertures 491 extendingtherethrough are also aligned with each other so as to define otheramortisseur winding receiving bores 501 through pole sections stacks511. Since the stacking and aligning of pole sections 481 may occurbefore, after or simultaneously with the stacking of laminations 457, aspreviously mentioned, the pole section stacking and aligning arerespectively illustrated by functional diagram boxes 513 and 515 in FIG.31 in parallel flow relation with box 493 which illustrates thelamination stacking. Albeit not shown for the purpose of brevity, it isunderstood that suitable equipment may be employed to effect thestacking and alignment of pole sections 481 into stacks 511 thereof.

Subsequent to the stacking and aligning of laminations 457 and polesections 481, as discussed above, a plurality of amortisseur windingbars 517 of a non-magnetic material yet having good electricalconductivity properties, such as aluminum, copper or alloys thereof forinstance, may be inserted or otherwise placed or located in bores 501extending through both lamination stack 455 and pole section stack 511,as best seen in FIGS. 29 and 32. Of course, the insertion of bars 517through lamination stack 455 and pole section stacks 511 may occursimultaneously or one before the other, as desired; therefore, theinsertion of the bars into the lamination stack and the pole sectionstacks are respectively illustrated in functional diagram boxes 519 and521 in parallel flow relation with each other in FIG. 31. While bars 517are disclosed herein as being inserted into bores 501 of both laminationstack 455 and pole section stack 511 subsequent to the respectivestacking and aligning thereof, it is contemplated that the bores of boththe laminations 457 and pole sections 477 may be assembled directly ontoor about the bars arranged in predetermined positions so as toaccommodate the stacking and alignment of the laminations and the polesections thereon within the scope of the invention so as to meet atleast some of the objects thereof. Of course, it is also contemplatedthat suitable equipment and/or fixtures (not shown) may be utilized toeffect the placement of bars 517 with respect to bores 501 in laminationstack 457 and pole section stacks 511, respectively.

With bars 517 so placed in lamination stack 457 and pole section stacks511, the pole section stacks may be disposed, placed or otherwiselocated within slots 499 of lamination stack 455 in preselectedpositions therein. In these preselected positions, it may be noted thatopposite sidewalls 485, 487 of pole sections stacks 511 are arrangedgenerally in opposed facing relations with opposed sidewalls 471, 473 onadjacent ones of pole sections 467 on the lamination stack, and arcuatewalls 483 of the pole section stacks are arranged so as to generallydefine in part peripheral portion 493 of rotor 453 or at least begenerally coextensive therewith. Of course, free end walls 489 of polesection stacks 511 are disposed in spaced relation opposite end walls475 of lamination stack 455 when the pole section stacks are in theirrespective preselected positions. The disposition of pole section stacks511 in their respective preselected positions is illustrated byfunctional diagram box 523 in FIG. 31.

Either before, after or simultaneously with the placement of polesection stacks 511 in their preselected positions, as discussed above,sets of magnets 89, 91 may also be disposed, placed or otherwise locatedin preselected positions between opposite sidewalls 185, 187 of the polesection stacks and opposed sidewalls 171, 173 of pole sections 467 onlamination stack 455 adjacent the pole section stacks, respectively.Albeit desirable to abut opposite sidewalls 185, 187 of pole sectionstack 511 and opposite faces 109 of the magnets with opposed sidewalls171, 173 of pole sections 467 on lamination stack 455, it is believedthat the magnets may be generally loosely disposed therebetween, i.e.,with respect to the manufacturing tolerances of the magnets, the polesection stack and the lamination stack, respectively. Of course, it iscontemplated that suitable equipment and/or fixturing may be employed toprovide for the location of pole section stacks 511 and magnets 89, 91either simultaneously or in any other order about rotor 453. Even thoughmagnets 89, 91 may be located in their respective preselected positionseither before, after or simultaneously with the placement of polesection stacks 511 in their respective preselected positions, aspreviously mentioned, the location of the magnets is illustrated forpurpose of clarity in functional diagram box 525 in FIG. 31 separatefrom box 523 which illustrates the location of the pole section stacks.If laminations 457 and pole sections 481 are assembled into respectivestacks 455 and 511 thereof on bars 517, as contemplated and previouslymentioned hereinabove, it is further contemplated that magnets 89, 91may be assembled with the respective stacks while they are mounted onthe bars within the scope of the invention so as to meet at least someof the objects thereof.

Subsequent to the location of magnets 89, 91 with respect to laminationstack 455 and pole section stack 511, as discussed above, a pair of endrings 527, 529 are positioned or otherwise mounted generally inface-to-face relation with opposite end faces 503, 505 of the laminationstack and on the opposite ends of bars 517 extending through bores 501in both pole section stacks 511 and the lamination stack past the endfaces thereof, respectively. End rings 527, 529 are formed of anon-magnetic material having acceptable electrical conductivityproperties, such as aluminum, copper or alloys thereof for instance, anda plurality of apertures 531 are provided through the end ringsgenerally in alignment with bores 501 in both lamination stack 455 andpole section stacks 511 so as to receive the opposite ends of bars 517when the end rings are mounted thereto, respectively. End rings 527, 529are respectively provided with generally radially spaced outerperipheral edges 533 and inner peripheral edges 535, and the outerperipheral edges are disposed at least adjacent peripheral portion 493of rotor 453 while the inner peripheral edges are disposed at leastadjacent shaft receiving bore 509 of the rotor. The mounting of endrings 527, 529, as discussed above, is illustrated by functional diagrambox 537 in FIG. 31, and of course, it is also contemplated that suitableequipment and/or fixturing (not shown) may be employed to effect themounting of the end rings.

With opposite ends of bars 517 so received in apertures 531 of end rings527, 529, the bars and end rings are secured together in displacementpreventing engagement and electrical contacting engagement by suitablemeans, such as soldering or the like for instance, thereby to formamortisseur winding 539 in rotor 453; however, it is contemplated thatother means may be employed to effect the securement of the bars and theend rings within the scope of the invention so as to meet the objectsthereof. The securement of end rings 527, 529 to bars 517, as discussedabove, is illustrated by functional diagram box 541 in FIG. 31.

When end rings 527, 529 are so mounted in caging relation withlamination stack 455 and pole section stacks 511 and secured to theopposite ends of bars 517, as previously discussed, hardenablenon-magnetic material 495 is provided or otherwise introduced into slots499 of lamination stack 455 between the end rings so as to fill theinterstices within the slots between pole section stacks 511, polesections 467 on the lamination stack and magnets 89, 91 disposedtherebetween, as best seen in FIG. 33 and as illustrated by functionaldiagram box 543 in FIG. 31. As previously mentioned, upon thesolidification of hardenable material 495 in slots 499, the hardenablematerial and magnets 89, 91 define the magnetic polarity of pole sectionstacks 511 from that of pole sections 467 on lamination stack 455, andsince the hardenable material is engaged between opposite faces 113 ofthe magnets and flanges 477, 479 on the lamination stack, the hardenablematerial also serves to maintain or retain the magnets in theirpreselected positions against displacement therefrom respectively. It isalso believed that the hardenable material may assist the amortisseurwinding 539 in retaining pole section stacks 511 against displacementfrom their respective preselected positions in slots 499.

To complete the method of making rotor 453, peripheral portion 493thereof may be turned or otherwise machined so as to provide the rotorwith a preselected outside diameter generally in the same manner asdiscussed hereinabove with respect to the machining of rotor 43.

Upon the completion of rotor 453, bore 509 thereof may be mounted ingripping or displacement preventing engagement with shaft 155 generallyin the same manner as discussed hereinbefore with respect to rotor 43.Thus, rotor 453 and shaft 155 comprise rotatable assembly 451 which ismounted or otherwise arranged with stationary assembly 161 ofelectronically commutated motor 45 so as to be operable therewithgenerally in the same manner as discussed hereinbefore with respect torotatable assembly 151. Of course, it is also contemplated that magnets89, 91 in rotatable assembly 451 may be magnetized in the same manner aspreviously discussed hereinabove.

From the foregoing, it is now apparent that a novel electronicallycommutated motor 45, novel rotatable assemblies 151, 451, a novelstationary assembly 161 and, a novel lamination 41 have been presentedmeeting the objects set out hereinbefore, as well as others, and thatchanges as to the precise arrangements, shapes, details and connectionsof the component parts may be made by those having ordinary skill in theart without departing from the spirit of the invention or the scopethereof as set out in the claims which follow.

What I claim as new and desire to secure by Letters Patent of the UnitedStates is:
 1. A lamination adapted to be used in a core of adynamoelectric machine, the lamination comprising:a unitary body ofgenerally thin ferromagnetic material; an outer peripheral edge of saidbody; an inner peripheral edge on said body and spaced generallyradially from said outer peripheral edge; a plurality of generallyV-shaped openings through said body between said outer peripheral edgeand said inner peripheral edge and disposed with respect to each othergenerally in arcuate spaced relation about said body, said openings eachhaving first and second leg parts converging toward each other generallyin a direction from said outer peripheral edge toward said innerperipheral edge, said first and second leg parts including first andsecond pairs of opposed side edges, first and second end edgesinterposed between said first and second side edge pairs and spacedadjacent said outer peripheral edge, and a common end edge interposedbetween one of said opposed side edges of said first and second sideedge pairs and spaced adjacent said inner peripheral edge, respectively;a plurality of first pole sections on said body between opposite ones ofsaid one opposed side edges of said first and second side edge pairs inadjacent ones of said openings and extending generally between saidouter peripheral edge and said inner peripheral edge, respectively; aplurality of bridges on said body between said common end edges and saidinner peripheral edge and integrally interconnected between adjacentones of said first pole sections, respectively; a plurality of secondpole sections on said body disposed between the other of said opposedside edges of said first and second side edge pairs and extending fromsaid outer peripheral edge generally toward said inner peripheral edge,said second pole sections including a plurality of free end edgesinterposed between said other opposed side edges of said first andsecond side edge pair and spaced from said bridges, respectively; and aplurality of pairs of bridges on said body between said outer peripheraledge and said first and second end edges of said first and second legparts and integrally interconnected between said first pole sections andsaid second pole sections, respectively.
 2. A lamination adapted to beused in a core of a dynamoelectric machine, the lamination comprising:aunitary body of generally thin ferromagnetic material; a pair ofgenerally radially spaced apart peripheral edges on said body; aplurality of openings through said body between said peripheral edgesthereof, respectively; a plurality of first pole sections on said bodybetween said openings and extending generally between said peripheraledges, respectively; a plurality of means on said body interposedbetween said openings and one of said peripheral edges for bridgingbetween adjacent ones of said first pole sections of said pluralitythereof, respectively; a plurality of second pole sections extendingfrom the other of said peripheral edges into said openings between saidadjacent ones of said first pole sections and in spaced relationtherewith, respectively; and a plurality of pairs of other means on saidbody interposed between said openings and said other peripheral edge forbridging between said first pole sections and said second pole sections,respectively.
 3. A lamination as set forth in claim 2 wherein saidsecond pole sections include a pair of opposite tabs integrally formedtherewith and extending into said openings, respectively.
 4. Alamination as set forth in claim 2 further comprising a plurality ofamortisseur winding accommodating openings extending through at leastone of said first pole sections and said second pole sections,respectively.
 5. A lamination as set forth in claim 2 wherein saidadjacent ones of said first pole sections include a pair of opposedmarginal edges disposed between said first named bridging means and saidother bridging means pair so as to define in part said openings,respectively, and a pair of opposite marginal edges on said other polesections arranged generally in facing relation with said opposedmarginal edges so as to also define in part said openings, respectively.6. A lamination as set forth in claim 2 wherein said openings include afirst pair of opposed marginal edges on said adjacent ones of said firstpole sections, a second pair of opposite marginal edges on said secondpole sections and arranged generally in opposed relation with said firstopposed marginal edge pair, a common marginal edge on said first namedbridging means and interposed between said first opposed marginal edgepair, and a pair of end marginal edges on said other bridging means pairand interposed between opposed ones of said marginal edges of said firstopposed marginal edge pairs and said second opposite marginal edgepairs, respectively.
 7. A lamination as set forth in claim 6 wherein theopenings further include a free end edge on said second pole sectionsinterposed between said second opposite marginal edge pair and spacedadjacent said common marginal edge in opposed relation therewith,respectively.
 8. A lamination adapted to be used in a core of adynamoelectric machine, the lamination comprising:a unitary body ofgenerally thin ferromagnetic material; a plurality of first polesections spaced apart from each other generally about said body; aplurality of means on said body and interposed between adjacent ones ofsaid first pole sections for bridging therebetween, respectively; aplurality of second pole sections on said body and interposed in spacedrelation between said adjacent ones of said first pole sections;respectively; and a plurality of pairs of other means on said body andinterposed between said adjacent ones of said first pole sections andsaid second pole sections for bridging therebetween, respectively.
 9. Alamination as set forth in claim 8 further comprising a peripheral edgeon said body and defined by said first name pole sections, said otherpole sections and said other bridging means pairs, respectively.
 10. Alamination as set forth in claim 8 further comprising a peripheral edgeon said body defined by said first named pole sections and said firstnamed bridging means, respectively.
 11. A lamination as set forth inclaim 8 further comprising a pair of peripheral edges on said bodyarranged generally in radially spaced relation with each other, one ofsaid peripheral edges being respectively defined by said first namedpole sections, said other pole sections and said other bridging meanspairs and the other of said peripheral edges being respectively definedby said first named pole sections and said first named bridging means.12. A lamination as set forth in claim 8 wherein said other polesections each includes a pair of tabs integral therewith and extendinggenerally toward said adjacent ones of said first named pole sections,respectively.
 13. A lamination as set forth in claim 8 furthercomprising a plurality of generally V-shaped openings extending throughsaid body and defined between said second pole sections and saidadjacent ones of said first pole sections and between said first namedbridging means and said other bridging means pairs, respectively.
 14. Alamination as set forth in claim 8 further comprising a plurality ofopenings extending through said body, each of said openings of saidplurality thereof including a first pair of edges on said adjacent onesof said first pole sections, a second pair of edges on said second polesections and arranged generally in opposed relation with said first edgepair, a common edge on said first named bridging means and interposedbetween said first edge pair, and a pair of spaced apart end edgesinterposed between adjacent opposed edges of said first and second edgepairs and arranged generally in opposed relation with said common edge,respectively.
 15. A lamination as set forth in claim 8 wherein saidsecond pole sections respectively include an end portion spaced adjacentsaid first named bridging means, and an opening intersecting only withsaid end portion and extending through said body.
 16. A rotatableassembly adapted to be used in a dynamoelectric machine, the rotatableassembly comprising:a ferromagnetic core having a peripheral portioninterposed between a pair of opposite end faces; a bore in said coreintersecting with said opposite end faces; a plurality of slotsintersecting with said peripheral portion between said opposite endfaces and arranged generally in arcuate spaced relation with each otherabout said core, said slots each including a pair of opposed sidewallsconverging generally toward each other in a direction from saidperipheral portion toward said bore, and a base wall generally adjacentsaid bore interposed between said opposed sidewalls; a plurality ofpairs of opposed flanges on said core extending between said oppositeend faces at least adjacent said peripheral portion and said flangepairs each being arranged so as to protrude into said slots past saidopposed sidewalls thereof, respectively; a plurality of ferromagneticpole sections arranged in said slots between said opposed sidewallsthereof and said opposed flanges, respectively, said pole sections eachincluding another peripheral portion arranged so as to be at leastgenerally coextensive with said first named peripheral portion on saidcore, a pair of opposite sidewalls converging generally toward eachother in a direction from said another peripheral portion toward saidbore so as to be arranged generally in facing relation with said opposedsidewalls of said slots and said opposed flanges, another base wallinterposed between said opposite sidewalls and arranged generally infacing relation with said first named base wall, and a pair of oppositeseats integral with said opposite sidewalls at least generally adjacentsaid another base wall and extending generally toward said opposedsidewalls of said slots, respectively; a plurality of pairs of magneticmaterial elements arranged within said slots in abutting engagementbetween said opposed sidewalls of said slots and said opposite sidewallsof said pole sections and with a part of said magnet material elementpairs engaged with said seats on said pole sections, respectively; and ahardenable non-magnetic material solidified in place within said slotsso as to generally fill the interstices thereof between said flangepairs and said magnetic material element pairs and between said polesections and parts of said core adjacent thereto, said hardenablematerial acting with said magnetic material element pairs to not onlydefine the polarity of said pole sections from said adjacent core partsbut also to retain said pole sections against displacement from saidslots, respectively.
 17. A rotatable assembly adapted to be used in adynamoelectric machine, the rotatable assembly comprising:aferromagnetic core having a plurality of first pole sections of likepolarity spaced generally thereabout and defining in part a peripheralportion of said core; a plurality of second pole sections having apolarity opposite that said first pole sections of and arranged inselected positions about said core between adjacent ones of said firstpole sections, respectively; a plurality of pairs of magnetic materialelements engaged between said second pole sections and said adjacentones of said first pole sections, respectively; and a hardenablenon-magnetic material solidified in said core between said first andsecond pole sections and said pairs of magnetic material elements so asto not only define the polarities of said first and second pole sectionsfrom each other but also prevent displacement of said second polesections from their selected positions, respectively.
 18. A rotatableassembly as set forth in claim 17 wherein said second pole sectionsinclude means therein for gripping engagement with said hardenablenon-magnetic material solidified in said core, and said first polesections include means arranged at least adjacent said peripheralportion for abutment with said hardenable non-magnetic materialsolidified in said core, the coaction of said gripping engagement meansand said abutment means with said hardenable non-magnetic materialsolidified in said core acting to prevent the displacement of saidsecond pole sections from their selected positions, respectively.
 19. Arotatable assembly adapted for use in a dynamoelectric machine, therotatable assembly comprising:a ferromagnetic core having a peripheralportion; a plurality of ferromagnetic pole sections; a plurality ofmeans in said core at least adjacent said peripheral portion forreceiving said pole sections; and means for magnetically defining thepolarity of said pole sections from parts of said core adjacent theretoand for retaining said pole sections against displacement from saidreceiving means generally toward said peripheral portion of said core,said defining and retaining means including a plurality of sets ofmagnetic material elements abutted in engagement between said polesections and said adjacent parts of said core, and a hardenablenon-magnetic material solidified in said receiving means between saidpole sections, said adjacent parts of said core and said magneticmaterial element sets, respectively.
 20. A lamination as set forth inclaim 1 wherein said second pole sections include a plurality of otheropenings intersecting with said free end edges, respectively.
 21. Astationary assembly adapted to be used in a dynamoelectric machine, thestationary assembly comprising;a ferromagnetic core having a peripheralportion interposed between a pair of opposite end faces, said coreincluding a plurality of generally radially extending teeth each havingan inner tip defining in part a bore extending generally axially throughsaid core between said opposite end faces thereof, and a plurality ofslots arranged between adjacent ones of said teeth so as to intersectwith said bore and extending between said opposite end faces, each ofsaid slots having a top section and a bottom section with said topsection being adjacent said bore, respectively; a multi-stage windingarrangement associated with said core and having at least three windingstages each including a plurality of coils spanning a preselected numberof said teeth, and each of said coils having at least one conductor turnand a pair of opposite side turn portions, respectively, at least halfof said coils in each of said at least three winding stages having oneof said opposite side turn portions thereof sharing a plurality ofindividual ones of said slots with one of said opposite side turnportions of another coil in a same winding stage, said one opposite sideturn portion of said at least half of said coils and said one oppositeside turn portion of said another coil in said same winding stage beingdisposed in one of said top section and said bottom section of saidindividual ones of said slots, respectively, a first pair of said coilsin one of said winding stages of said at least three winding stageshaving one of said opposite side turn portions thereof disposed in oneof said top section and said bottom section of a first pair of saidslots and a second pair of said coils in another of said winding stagesof said at least three winding stages having one of said opposite sideturn portions thereof disposed in the other of said top section and saidbottom section of said first slot pair, respectively, a third pair ofsaid coils in one of said one winding stage and and said another windingstage having one of said opposite side turn portions thereof disposed inone of said top section and said bottom section of a second pair of saidslots and a fourth pair of said coils in a third one of said windingstages of said at least three winding stages having one of said oppositeside turn portions thereof disposed in the other of said top section andsaid bottom section of said second slot pair, respectively, a fifth pairof said coils in the other of said one winding stage and said anotherwinding stage having one of said opposite side turn portions thereofdisposed alone in a third pair of said slots, respectively, and a sixthpair of said coils in said third one of said winding stages having oneof said opposite side turn portions thereof disposed alone in a fourthpair of said slots, respectively.
 22. A stationary assembly as set forthin claim 19 wherein said slot plurality includes at least twenty sixslots.
 23. A stationary assembly as set forth in claim 19 wherein saidpreselected number of said teeth is at least three.
 24. A stationaryassembly as set forth in claim 19 wherein at least some of said coils inat least some of said winding stages of said at least three thereof areinterconnected and successively wound.
 25. A stationary assembly adaptedto be used in a dynamoelectric machine, the stationary assemblycomprising:a ferromagnetic core having a plurality of winding receivingslots therein; a multi-stage winding arrangement associated with saidslots of said plurality thereof and including at least three windingstages, each of said winding stages of said at least three thereofhaving a plurality of coils, each of said coils in said each windingstage having at least one conductor turn and a pair of opposite sideturn portions, respectively, most of said coils in said each windingstage having one of said opposite side turn portions thereof sharingindividual ones of said slots with one of said opposite side turnportions of other coils in the same winding stage, respectively, one ofsaid coils in two of said winding stages each having one of saidopposite side turn portions thereof disposed in one slot of a first pairthereof and another of said coils in said two winding stages each havingone of said opposite side turn portions thereof disposed in the otherslot of said first pair thereof, respectively, a third coil in one ofsaid two winding stages and one coil in a third one of said windingstages of said at least three winding stages each having one of saidopposite side turn portions thereof disposed in one slot of a secondpair thereof and a fourth coil in said one of said two winding stagesand another coil in said third one winding stage each having one of saidopposite side turn portions thereof disposed in the other slot of saidsecond pair thereof, and two coils in the other of said two windingstages and said third one winding stage each having said opposite sideturn portions thereof disposed in a third pair of said slots and afourth pair of said slots, respectively.
 26. A stationary assembly asset forth in claim 23 wherein said slot plurality comprises at leasttwenty-six slots.
 27. A stationary assembly as set forth in claim 23wherein said core includes a plurality of teeth interposed betweenadjacent ones of said slots, and said each coil in said each windingstage spanning at least three teeth.
 28. A stationary assembly as setforth in claim 23 wherein at least some of said coils in at least someof said winding stages span at least four of said slots, respectively.29. A stationary assembly as set forth in claim 23 wherein at least someof said coils in at least some of said winding stages are interconnectedand successively wound.
 30. A stationary assembly as set forth in claim23 wherein said slots each include a top section and a bottom section,respectively, and said one opposite side turn portion of all of saidcoils except said two coils in said other of said two winding stages andsaid third one winding stage being disposed in one of said top sectionand said bottom section, respectively.
 31. An electronically commutatedmotor as set forth in claim 26 wherein said some poles each include apair of opposite means extending therefrom into said receiving meansgenerally toward said adjacent other poles for seating engagement withsaid magnetic material element pairs, respectively.
 32. A stationaryassembly adapted to be used in a dynamoelectric machine, the stationaryassembly comprising:a ferromagnetic core having a plurality of windingreceiving slots; a multi-stage winding arrangement including a pluralityof winding stages each having a plurality of coils and each of saidcoils having at least one conductor turn with side turn portions thereofreceived in said slots of said plurality thereof, some of said coils insaid each winding stage having said side turn portions thereof sharingslots only with said side turn portions of other of said coils in thesame winding stage, two pairs of said coils in one of said windingstages having side turn portions sharing slots with side turn portionsof two pairs of said coils in another two of said winding stages,respectively, and another two pair of said coils in said another twowinding stages having side turn portions which do not share slots,respectively.
 33. An electronically commutated motor comprising:aferromagnetic stator having a bore therein; a plurality of windingreceiving slots in said stator and intersecting with said bore; amulti-stage winding arrangement associated with said slots of saidplurality thereof and including at least three winding stages adapted tobe commutated in at least one preselected sequence, each of said windingstages having a plurality of coils, each of said coils in said eachwinding stage having at least one conductor turn and a pair of oppositeside turn portions, respectively, some of said coils in said eachwinding stage having at least one of said opposite side turn portionsthereof disposed in individual ones of said slots with one of saidopposite side turn portions of another of said coils in a same windingstage, respectively, one of said coils of two winding stages each havingone of said opposite side turn portions thereof disposed in one slot ofa first pair thereof and another of said coils of said two windingstages each having one of said opposite side turn portions thereofdisposed in the other slot of said first slot pair, respectively, athird coil in one of said two winding stages and one coil in a thirdwinding stage each having one of said opposite side turn portionsthereof disposed in one slot of a second pair thereof and a fourth coilin said one of said two winding stages and another coil in said thirdwinding stage each having one of said opposite side turn portionsthereof disposed in the other slot of said second slot pair, and twocoils of said coil plurality in the other of said two winding stageseach having one of said opposite sides thereof disposed in a third pairof said slots, respectively; a rotor disposed at least in part withinsaid stator bore in magnetic coupling relation with said at least threewinding stages and including a peripheral portion interposed between apair of opposite end faces and arranged generally in coaxial relationwith said stator bore, a shaft receiving opening extending through saidrotor and intersecting with said opposite end faces, a plurality ofdiscrete first pole sections integrally interconnected with each otherand arranged in spaced relation generally about said rotor between saidopposite end faces thereof, respectively, a plurality of other slotsintersecting said peripheral portion between said opposite end faces andinterposed between adjacent ones of said first pole sections,respectively, said other slots of said plurality there each having apair of opposed sidewalls converging generally toward each other in adirection from said peripheral portion toward said shaft receivingopening with a base wall adjacent thereto interposed between saidopposed sidewalls, and a plurality of pairs of opposed flanges extendingbetween said opposite end faces at least adjacent said peripheralportion with said opposed flanges arranged so as to protrude into saidother slots past said opposed sidewalls thereof, respectively; aplurality of discrete second pole sections arranged in said other slotsbetween said opposed sidewalls thereof, respectively, said second polesections each including another peripheral portion arranged so as to beat least generally coextensive with said first named peripheral portion,a pair of opposite sidewalls converging generally toward each other in adirection from said another peripheral portion toward said shaftreceiving opening so as to be arranged generally in facing relation withsaid opposed sidewalls of said other slots and said opposed flanges, anend wall interposed between said opposite sidewalls and arrangedgenerally in facing relation with said base wall, and a pair of oppositeseats integral with said opposite sidewalls at least generally adjacentsaid end wall and extending generally toward said opposed sidewalls ofsaid other slots respectively; a plurality of pairs of magnetic materialelements arranged in abutting engagement between said opposed sidewallsof said other slots and said opposite sidewalls of said second polesections and with parts of said magnetic material element pairs engagedwith said seats on said second pole sections, respectively; and ahardenable non-magnetic material solidified in place within said otherslots generally filling them and disposed between said flanges, saidmagnetic material element pairs, said first pole sections and saidsecond pole sections so as to not only retain said second pole sectionsagainst displacement from said other slots but also to magneticallydefine the polarity of said first pole sections from that of said secondpole sections, respectively.
 34. An electronically commutated motorcomprising:a pair of ferromagnetic cores arranged at least in partgenerally in coaxial spaced relation with each other and with one ofsaid cores being rotatable relative to the other thereof; a plurality ofwinding stages arranged generally about one of said one and other coresand adapted to be commutated in at least one preselected sequence; aplurality of discrete magnetic pole sections arranged generally aboutthe other of said one and other cores so as to be disposed in magneticcoupling relation with said winding stages upon the commutation thereofin the at least one preselected sequence, respectively; a plurality ofmeans arranged generally about said other of said one and other coresfor receiving some of said pole sections in spaced relation betweenadjacent other pole sections, respectively; and means caged in saidreceiving means between said some pole sections and said adjacent otherpole sections not only for maintaining said some pole sections againstdispalcement from said receiving means but also for magneticallydefining the polarity of said some pole sections from that of saidadjacent other poles, respectively.
 35. An electronically commutatedmotor as set forth in claim 26 wherein said adjacent other poles eachinclude a pair of opposed flanges extending therefrom into saidreceiving means generally toward said some poles, said hardenablematerial having parts thereof caged between said opposed flange pair ofsaid plurality thereof and said magnetic material element pairs,respectively.
 36. An electronically commutated motor as set forth inclaim 26 wherein said adjacent other poles are structurallyinterconnected with each other and have a like polarity different thanthat of said some poles, respectively.
 37. An electronically commutatedmotor as set forth in claim 26 wherein said other of said one and othercores includes a pair of opposite end members, a plurality of openingsextending through at least one of said some poles and said other polesbetween said opposite end members, and means in said plurality ofopenings and associated with said opposite end members for definingtherewith an amortisseur winding of said other of said one and othercore.
 38. An electronically commutated motor comprising:a stationaryassembly including a ferromagnetic core with at least three windingstages arranged generally thereabout and adapted to be energized in apreselected sequence; a rotatable assembly including anotherferromagnetic core rotatably arranged with said first named core; aplurality of discrete first pole sections of like polarity arrangedgenerally about said another core in magnetic coupling relation withsaid at least three winding stages upon the energization thereof anddefining in part a peripheral portion of said another core,respectively; a plurality of discrete second pole sections of a polarityopposite that of said first pole sections and arranged generally inpreselected positions about said another core between adjacent ones ofsaid first pole sections in magnetic coupling relation with said atleast three winding stages upon the energization thereof, said secondpole sections also defining in part said peripheral portion of saidanother core, respectively; a plurality of pairs of magnetic materialelements engaged between said second pole sections and said adjacentones of said first pole sections and also seated on at least one of saidfirst and second pole sections, respectively; and a hardenablenon-magnetic material in said another core and solidified in placebetween said adjacent ones of said first pole sections, said second polesections and said magnetic material element pairs not only to retainsaid second pole sections against displacement from their preselectedpositions but also to magnetically define said second pole sections fromsaid adjacent ones of said first pole sections, respectively.
 39. Anelectronically commutated motor comprising:a rotatable assembly having aplurality of polar regions; a stationary assembly associated in magneticcoupling relation with said rotatable assembly and including a pluralityof winding receiving slots with the number of said slots being differentthan the product of an integer greater than zero multiplied by thenumber of said polar regions in said rotatable assembly, and amulti-stage winding arrangement having a plurality of winding stagesadapted for commutation in at least one preselected sequence with eachwinding stage having a plurality of coils distributed in said slotsgenerally about said stationary assembly.
 40. An electronicallycommutated motor comprising:a rotatable assembly having a plurality ofpolar regions; a stationary assembly associated in magnetic couplingrelation with said rotatable assembly, and said stationary assemblyincluding a plurality of winding receiving slots, and a multi-stagewinding arrangement having a plurality of winding stages adapted forcommutation in at least one preselected sequence with each winding stagehaving a plurality of coils distributed in said slots wherein the numberof said slots is equal to the product of an integer greater than zeromultiplied by the number of said polar regions in said rotatableassembly and with the product being increased or decreased by anotherinteger not less than one or greater than two.
 41. An electronicallycommutated motor as set forth in claim 40 further comprising a pluralityof means in said another core for receiving said second pole sections inthe preselected positions thereof and said magnet material elementpairs, said hardenable material being solidified in place within saidreceiving means, respectively.
 42. An electronically commutated motor asset forth in claim 40 wherein said adjacent ones of said first polesections each include a pair of flanges extending generally toward saidsecond pole sections, said hardenable material having parts thereofinterposed between said flanges and said magnetic material element pairsthereby to cage said second pole sections in their preselected positionsin said another core between said adjacent ones of said first polesections, respectively.
 43. An electronically commutated motor as setforth in claim 40 wherein said another core includes a boretherethrough, a shaft received in said bore, and means associated withsaid stationary assembly for rotatably journaling said shaft.
 44. Anelectronically commutated motor comprising:a pair of reltativelyrotatable ferromagnetic cores; a plurality of winding receiving slots inone of said cores; a multi-stage winding arrangement including aplurality of winding stages adapted to be energized in a preselectedsequence, each of said winding stages having a plurality of coils witheach of said coils thereof having at least one conductor turn with sideturn portions thereof received in said slots, some of said coils in saideach winding stage having side turn portions thereof sharing slots onlywith side turn portions of other of said coils in the some windingstage, two pairs of said coils in one of said winding stages having sideturn portions sharing slots with said side turn portions of two pairs ofsaid coils in another two of said winding stages, respectively, andanother pair of coils in one of said another two winding stages havingside turn portions which do not share slots; and a plurality of discretepole sections arranged generally about the other of said cores so as tobe magnetically coupled with said each winding stage upon theenergization thereof, respectively.
 45. An electronically commutatedmotor as set forth in claim 44 wherein said slot plurality includes atleast twenty-six slots.
 46. An electronically commutated motor as setforth in claim 44 wherein said each coil in said each winding stagespans at least four slots.
 47. An electronically commutated motor as setforth in claim 44 wherein each said coil in at least some of saidwinding stages are interconnected and successively wound.
 48. Anelectronically commutated motor as set forth in claim 44 wherein saidslots each include a top section and a bottom section, respectively, andmost of said coils of said plurality thereof being disposed in a lappedassociation with one side turn portion thereof positioned in one of saidtop section and bottom section of individual ones of said slots and withan opposite side turn portion thereof positioned in the other of saidtop section and bottom section of in other individual ones of saidslots.
 49. A rotatable assembly adapted to be used in a dynamoelectricmachine, the rotatable assembly comprising:a ferromagnetic core having aperipheral portion interposed between a pair of opposite end faces; aplurality of slots in said core extending between said opposite endfaces and intersecting with said peripheral portion, respectively; aplurality of ferromagnetic pole pieces disposed in said slots and eachhaving a pair of opposite seats extending therefrom, respectively; aplurality of sets of magnetic material elements arranged in said slotsbetween said pole pieces and said core so as to be engaged with saidopposite seats on said pole pieces, respectively; and a hardenablenon-magnetic material solidified within said slots and acting with saidmagnetic material element sets not only to define the polarity of saidpole pieces from that of parts of said core generally adjacent theretobut also to retain said pole pieces against displacement from saidslots, respectively.
 50. A rotatable assembly as set forth in claim 49further comprising a plurality of pairs of flanges on said core andextending into said slots at least adjacent said peripheral portion ofsaid core, respectively, said hardenable material being interconnectedbetween said flange pairs and said magnetic material elements sets,respectively.
 51. A rotatable assembly as set forth in claim 49 whereinsaid pole pieces each include a pair of opposite sidewalls, saidopposite seats extending from said opposite sidewalls, and said slotseach including a pair of opposed sidewalls, said magnetic materialelements sets being engaged between adjacent ones of said oppositesidewalls and said opposed sidewalls, respectively.
 52. A rotatableassembly as set forth in claim 49 wherein said hardenable material issolidified in place within said slots, respectively.
 53. A rotatableassembly as set forth in claim 49 a plurality of openings in at leastone of said core and said pole pieces and extending therethrough betweensaid opposite end faces, and means within said opening defining at leastin part an amortisseur winding of said core.